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Full text of "Yamaha Fazer 1000 Service Manual"

YAMAHA 




2001 



5LV1-AE1 



SBIVICE MANUAL 



FZS1000(N) 

SERVICE MANUAL 

©2000 by Yamaha Motor Co.Ltd. 

First edition, December 2000 

All rights reserved. Any reproduction or 

unauthorized use without the written 

permission of Yamaha Motor Co., Ltd. is 

expressly prohibited. 



NOTICE 

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers 
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- 
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles 
should have a basic understanding of mechanics and the techniques to repair these types of vehicles. 
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve- 
hicle unsafe and unfit for use. 

This model has been designed and manufactured to perform within certain specifications in regard to 
performance and emissions. Proper service with the correct tools in necessary to ensure that the ve- 
hicle will operate as designed. If there is any question about a service procedure, it is imperative that 
you contact a Yamaha dealer for any service information changes that apply to this model. This policy 
is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed- 
eral environmental quality objectives. 

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi- 
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and 
will appear in future editions of this manual where applicable. 



NOTE: 

•This Service Manual contains information regarding periodic maintenance to the emission control 
system. Please read this material carefully. 
• Designs and specifications are subject to change without notice. 



IMPORTANT INFORMATION 

Particularly important information is distinguished in this manual by the following. 



& 



The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR 
SAFETY IS INVOLVED! 



A WARNING 



CAUTION: 
NOTE: 



Failure to follow WARNING instructions could result in severe injury or death to 
the motorcycle operator, a bystander or a person checking or repairing the mo- 
torcycle. 

A CAUTION indicates special precautions that must be taken to avoid damage 
to the motorcycle. 

A NOTE provides key information to make procedures easier or clearer. 



HOW TO USE THIS MANUAL 

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive 
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid 
out with the individual steps in sequential order. 

® The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each 
page indicate the current chapter. Refer to "SYMBOLS" on the following page. 

(2) Each chapter is divided into sections. The current section title is shown at the top of each page, 
except in Chapter 3 ("Periodic Checks and Adjustments"), where the sub-section title(-s) appears. 

(In Chapter 3, "Periodic Checks and Adjustments", the sub-section title appears at the top of each 
page, instead of the section title.) 

(3) Sub-section titles appear in smaller print than the section title. 

(4) To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each 
removal and disassembly section. 

(D Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a 
disassembly step. 

(D Symbols indicate parts to be lubricated or replaced (see "SYMBOLS"). 

(7) A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of 
parts, notes in jobs, etc. 

(D Jobs requiring more information (such as special tools and technical data) are described sequen- 
tially. 




ENG % 




REMOVING THE CLUTCH 

1 . Straighten the lock washer ta 

2. Loosen: 

•clutch boss nut© 
NOTE: 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the clutch cover 




Remove the parts in the order listed. 




Engine oil 




Refer to "CHANGING THE ENGINE OIL" 
in chapter 3. 




Clutch cable 


1 




2 


Clutch cover 


1 




3 


Clutch cover gasket 


1 




4 


Dowel pin 


2 


For installation, reverse the removal 
procedure. 



CHECKING THE FRICTION PLATES 

The following procedure applies to all of the fric- 
tion plates. 
1. Check: 
•friction plate 

Damage/wear -y Replace the friction plates 

as a set. 



© 



GEN 
INFO 


ffi^ 



(D 




CHK 
ADJ 


<& 



ENG 



M 



<Z> 



CARB 


7 



TRBL 
SHTG 


9 

• 



© 




© 




SPEC 



® 



CHAS 



<?fc§ 



COOL 



tt 



ELEC 



<^eg 



@ 





II 



i 



@> 



1 



i 



^ 



New 



SYMBOLS 

The following symbols are not relevant to every 

vehicle. 

Symbols ©to (9) indicate the subject of each 

chapter. 

® General information 

(2) Specifications 

(3) Periodic checks and adjustments 
Chassis 

(5) Engine 

(D Cooling system 

(7) Carburetor(-s) 

(8) Electrical system 

(9) Troubleshooting 



Symbols © to © indicate the following. 

© Serviceable with engine mounted 

©Filling fluid 

© Lubricant 

© Special tool 

©Tightening torque 

© Wear limit, clearance 

© Engine speed 

© Electrical data 



Symbols© to © in the exploded diagrams indi- 
cate the types of lubricants and lubrication 
points. 

@ Engine oil 

©Gear oil 

© Molybdenum disulfide oil 

@ Wheel bearing grease 

© Lithium soap base grease 

© Molybdenum disulfide grease 

Symbols© to © in the exploded diagrams indi- 
cate the following: 

© Apply locking agent (LOCTITE®) 
© Replace the part 



TABLE OF CONTENTS 



GENERAL INFORMATION 



#^ 



GEN 
INFO 




SPECIFICATIONS 



SPEC 




PERIODIC CHECKS AND 
ADJUSTMENTS 



<& 



CHK 
ADJ 




CHASSIS 



'0 



CHAS W* 




ENGINE 



M 



ENG 




COOLING SYSTEM 



X 



COOL 




CARBURETORS 



CARB 




ELECTRICAL SYSTEM 



ELEC 




TROUBLESHOOTING 



TRBL 
SHTG 




GEN 
INFO 


#^ 



CHAPTER 1 
GENERAL INFORMATION 

MOTORCYCLE IDENTIFICATION 1-1 

VEHICLE IDENTIFICATION NUMBER 1-1 

MODEL CODE 1-1 

IMPORTANT INFORMATION 1-2 

PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2 

REPLACEMENT PARTS 1-2 

GASKETS, OIL SEALS AND O-RINGS 1-2 

LOCK WASHERS/PLATES AND COTTER PINS 1-2 

BEARINGS AND OIL SEALS 1-3 

CIRCLIPS 1-3 

CHECKING THE CONNECTIONS 1-4 

SPECIAL TOOLS 1-5 



MOTORCYCLE IDENTIFICATION 



GEN 
INFO 


#^ 




GENERAL INFORMATION 
MOTORCYCLE IDENTIFICATION 

EAS00017 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number® is stamped 
into the right side of the steering head. 



MODEL CODE 

The model code label ® is affixed to the frame. 
This information will be needed to order spare 
parts. 



1-1 



IMPORTANT INFORMATION 



GEN 
INFO 


#^ 




IMPORTANT INFORMATION 

PREPARATION FOR REMOVAL AND DIS- 
ASSEMBLY 

1 . Before removal and disassembly, remove all 
dirt, mud, dust and foreign material. 

2. Use only the proper tools and cleaning 
equipment. 

Refer to the "SPECIAL TOOLS" section. 

3. When disassembling, always keep mated 
parts together. This includes gears, cylin- 
ders, pistons and other parts that have been 
"mated" through normal wear. Mated parts 
must always be reused or replaced as an as- 
sembly. 

4. During disassembly, clean all of the parts 
and place them in trays in the order of disas- 
sembly. This will speed up assembly and al- 
low for the correct installation of all parts. 

5. Keep all parts away from any source of fire. 



REPLACEMENT PARTS 

1 . Use only genuine Yamaha parts for all re- 
placements. Use oil and grease recom- 
mended by Yamaha for all lubrication jobs. 
Other brands may be similar in function and 
appearance, but inferior in quality. 



GASKETS, OIL SEALS AND O-RINGS 

1. When overhauling the engine, replace all 
gaskets, seals and O-rings. All gasket sur- 
faces, oil seal lips and O-rings must be 
cleaned. 

2. During reassembly, properly oil all mating 
parts and bearings and apply grease onto 
the oil seal lips with greace. 



LOCK WASHERS/PLATES AND COTTER 
PINS 

1. After removal, replace all lock wash- 
ers/plates® and cotter pins. After the bolt or 
nut has been tightened to specification, bend 
the lock tabs along a flat of the bolt or nut. 



1-2 



IMPORTANT INFORMATION 



GEN 
INFO 


#^ 





^— - 



BEARINGS AND OIL SEALS 

1. Install bearings and oil seals so that the 
manufacturer's marks or numbers are vis- 
ible. When installing oil seals, apply a light 
coat of lithium soap base grease onto the oil 
seal lips. Oil bearings liberally when instal- 
ling, if appropriate. 

© Oil seal 

CAUTION: 

Do not spin the bearing with compressed air 
because this will damage the bearing sur- 
faces. 



Bearing 



®^> 


J 




////$// 


+V / / / / / 

"////// 





CIRCLIPS 

1 . Before reassembly, check all circlips careful- 
ly and replace damaged or distorted circlips. 
Always replace piston pin clips after one use. 
When installing a circlip 0, make sure that 
the sharp-edged corner (2) is positioned op- 
posite the thrust (3) that the circlip receives. 

@ Shaft 



1-3 



CHECKING THE CONNECTIONS 



GEN 
INFO 


#^ 
















/£) )^^\ 




"7T 








j( 


I 


>; 
















I802C 


107 



CHECKING THE CONNECTIONS 

Check the leads, couplers, and connectors for 
stains, rust, moisture, etc. 

1. Disconnect: 
•lead® 

• coupler (D 
•connector® 

2. Check: 
•lead 
•coupler 
•connector 

Moisture — ► Dry with an air blower. 
Rust/stains -+ Connect and disconnect sev- 
eral times. 

3. Check: 

•all connections 
Loose connection -+ Connect properly. 

NOTE: 

If the pin ® on the terminal is flattened, bend it 
up. 

4. Connect: 
•lead 
•coupler 
•connector 

NOTE: 

Make sure that all connections are tight. 

5. Check: 
•continuity 

(with a pocket tester) 



p. 



Pocket tester 
90890-03112 



NOTE: 

• If there is no continuity, clean the terminals. 
•When checking the wire harness, perform 

steps 1 to 3. 
•As a quick remedy, use a contact revitalizer 

available at most part stores. 



1-4 



SPECIAL TOOLS 



GEN 
INFO 


#^ 



SPECIAL TOOLS 

The following special tools are necessary for complete and accurate tune-up and assembly. Use only 
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools 
or improvised techniques. Special tools, part numbers or both may differ depending on the country. 
When placing an order, refer to the list provided below to avoid any mistakes. 



Tool No. 



Tool name/Function 



Illustration 



90890-01080 



Rotor puller 



This tool is used to remove the generator 
rotor. 




90890-01235 



Rotor holding tool 

This tool is used to hold the generator rotor 
when removing or installing the generator 
rotor bolt or pickup coil rotor bolt. 




90890-01304 



Piston pin puller set 



This tool is used to remove the piston pins. 




90890-01312 



Fuel level gauge 



This tool is used to measure the fuel level in 
the float chamber. 



p fl 



Radiator cap 

tester 

90890-01325 

Adapter 

90890-01352 



Radiator cap tester 
Adapter 

These tools are used to check the cooling 
system. 




90890-01403 



Steering nut wrench 



This tool is used to loosen or tighten the 
steering stem ring nuts. 




90890-01447 



Damper rod holder 

This tool is used to hold the damper rod as- 
sembly when loosening or tightening the 
damper rod assembly bolt. 




1-5 



SPECIAL TOOLS 



GEN 
INFO 


#^ 



Tool No. 



Tool name/Function 



Illustration 



90890-01426 



Oil filter wrench 



This tool is needed to loosen or tighten the 
oil filter cartridge. 




90890-01434 



Rod holder 



This tool is used to support the damper ad- 
justing rod. 




Rod puller 
90890-01437 
Rod puller 
attachment 
90890-01436 



Rod puller 

Rod puller attachment 

These tools are used to pull up the front 
fork damper rod. 




Fork seal driver 
weight 

90890-01367 
Fork seal driver 
attachment (043) 
90890-01374 



Fork seal driver weight 

Fork seal driver attachment (043) 

This tool is used to install the front fork's oil 
seal and dust seal. 





90890-03008 



Micrometer (50 ~ 75 mm) 



This tool is used to measure the piston skirt 
diameter. 




Vacuum gauge 
90890-03094 



Vacuum gauge 



This guide is used to synchronize the car- 
buretors. 




Compression 

gauge 

90890-03081 

Compression 

gauge adapter 

90890-04136 



Compression gauge 
Compression gauge adapter 

These tools are used to measure engine 
compression. 




90890-03112 



Pocket tester 



This tool is used to check the electrical sys- 
tem. 





90890-03113 



Engine tachometer 



This tool is used to check engine speed. 




1-6 



SPECIAL TOOLS 



GEN 
INFO 


#^ 



Tool No. 



Tool name/Function 



Illustration 



90890-03141 



Timing light 



This tool is used to check the ignition tim- 
ing. 




90890-03173 



Carburetor angle driver 2 



This tool is used to turn the pilot screw 
when adjusting the engine idling speed. 




Valve spring com- 
pressor 
90890-04019 
Attach me nht 
90890-04108 
90890-04114 



Valve spring compressor 

Valve spring compressor attachment 

These tools are used to remove or install 
the valve assemblies. 




Middle driven shaft 
bearing driver 
90890-04058 
Mechanical seal 
installer 
90890-04078 



Middle driven shaft bearing driver 
Mechanical seal installer 

These tools are used to install the water 
pump seal. 




90890-04086 



Universal clutch holder 

This tool is used to hold the clutch boss 
when removing or installing the clutch boss 
nut. 




90890-04111 
90890-04116 



Valve guide remover (o4) 
Valve guide remover (o4.5) 

This tool is used to remove or install the 
valve guides. 




90890-04112 
90890-04117 



Valve guide installer (o4) 
Valve guide installer (o4.5) 



This tool is used to install the valve guides. 




90890-04113 
90890-04118 



Valve guide reamer (o4) 
Valve guide reamer (o4.5) 

This tool is used to rebore the new valve 
guides. 




90890-06754 



Ignition checker 



This tool is used to check the ignition sys- 
tem components. 




1-7 



SPECIAL TOOLS 



GEN 
INFO 


#^ 



Tool No. 


Tool name/Function 


Illustration 


90890-85505 


Yamaha bond No. 1215 

This bond is used to seal two mating sur- 
faces (e.g., crankcase mating surfaces). 


^ 



1-8 



SPEC 


o- 



CHAPTER 2. 
SPECIFICATIONS 

GENERAL SPECIFICATIONS 2-1 

ENGINE SPECIFICATIONS 2-2 

CHASSIS SPECIFICATIONS 2-11 

ELECTRICAL SPECIFICATIONS 2-15 

TIGHTENING TORQUES 2-18 

GENERAL TIGHTENING TORQUES 2-18 

ENGINE TIGHTENING TORQUES 2-19 

CHASSIS TIGHTENING TORQUES 2-22 

LUBRICATION POINTS AND LUBRICANT TYPES 2-23 

ENGINE 2-23 

CHASSIS 2-24 

COOLING SYSTEM DIAGRAMS 2-25 

ENGINE OIL LUBRICATION CHART 2-29 

LUBRICATION DIAGRAMS 2-30 

CABLE ROUTING 2-35 



SPEC 


o- 



GENERAL SPECIFICATIONS 



SPEC 


o- 



SPECIFICATIONS 



GENERAL SPECIFICATIONS 



Item 


Standard 


Limit 


Model code 


5VL1 (A) (B) (D) (DK) (E) (GB) (GR) (I) 
(N) (NL) (S) (SF) (CH) (P) 


••• 




5LV2 (F) 


••• 




5LV3 (D) 


••• 




5LV4 (AUS) 


••• 


Dimensions 






Overall length 


2,125 mm 


••• 


Overall width 


765 mm 


••• 


Overall height 


1,190 mm 


••• 


Seat height 


820 mm 


••• 


Wheelbase 


1 ,450 mm 


••• 


Minimum ground clearance 


140 mm 


••• 


Minimum turning radius 


2,900 mm 


••• 


Weight 






Wet (with oil and a full fuel tank) 


231 kg 


••• 


Dry (without oil and fuel) 


208 kg 


••• 


Maximum load (total of cargo, rider, 


189 kg 


••• 


passenger, and accessories) 







2-1 



ENGINE SPECIFICATIONS 



SPEC 


o- 



ENGINE SPECIFICATIONS 



Item 


Standard 


Limit 


Engine 

Engine type 

Displacement 

Cylinder arrangement 

Bore x stroke 

Compression ratio 

Engine idling speed 

Vacuum pressure at engine idling 

speed 

Standard compression pressure 

(at sea level) 


Liquid-cooled, 4-stroke, DOHC 

998 cm 3 

Forward-inclined parallel 4-cylinder 

74 x 58 mm 

11.4 : 1 

1,050 ~ 1,150 r/min 

30 kPa (225 mm Hg) 

1 ,450 kPa (14.5 kg/cm 2 ) at 400 r/min 


••• 


Fuel 

Recommended fuel 
Fuel tank capacity 

Total (including reserve) 

Reserve only 


Regular unleaded gasoline 

21 L 
4.0 L 


••• 

••• 
••• 


Engine oil 

Lubrication system 
Recommended oil 

Temp. °C 

-20-10 10 20 30 40 

i i i i i i i 


Wet sump 

SAE20W40SE or SAE10W30SE 

3.7 L 

2.8 L 

3.0 L 

45kPaat 1,100 r/min 

(0.45 kg/cm 2 at 1 ,1 00 r/min) 

490 ~ 570 kPa (4.9 ~ 5.7 kg/cm 2 ) 


••• 
••• 

••• 
••• 
••• 

••• 
••• 

••• 


Qua 
Tol 
Wi 
rep 
Wi 

Oil i 

Reli 


intit 1 

tala 
thoi 
)lac 
tho 
Dres 

ef v 




i i 
i i 








10W/30 ! 




/ 

litioi 
jt oi 
erne 
il filt 
sun 

alve 


10W/40 






20W/40 






| 20W/50 

jnt 

I filter cartridge 

mt 

er cartridge rep 

3 (hot) 

opening press 


11750703 

ilacement 
ure 



2-2 



ENGINE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Oil filter 






Oil filter type 


Cartridge (paper) 


••• 


Bypass valve opening pressure 


180 ~ 220kPa(1.8 ~ 2.2 kg/cm 2 ) 


••• 


Oil pump 






Oil pump type 


Trochoid 


••• 


Inner-rotor-to-outer-rotor-tip 


0.09 - 0.15 mm 


••• 


clearance 






Outer-rotor-to-oil-pump-housing 


0.03 ~ 0.08 mm 


••• 


clearance 






Cooling system 






Radiator capacity 


2.4 L 




Radiator cap opening pressure 


95-125 kPa (0.95 ~ 1.25 kg/cm 2 ) 


••• 


Radiator core 






Width 


340 mm 


••• 


Height 


238 mm 


••• 


Depth 


24 mm 


••• 


Coolant reservoir 






Capacity 


0.3 L 


••• 


Water pump 






Water pump type 


Single-suction centrifugal pump 


••• 


Reduction ratio 


68/43 x 28/28(1.581) 


••• 


Max. impeller shaft tilt 


••• 


0.15 mm 


Starting system type 


Electric starter 




Spark plugs 






Model (manufacturer) x quantity 


CR9E/U27ESR-N (NGK/DENSO) x 4 


••• 


Spark plug gap 


0.7 - 0.8 mm 


••• 


Cylinder head 






Max. warpage 


••• 


0.1 mm 


* 






^ 




i 


i i 


t M 








^ 


y- 






f V 









2-3 



ENGINE SPECIFICATIONS 



SPEC 


o- 



Item 



Standard 



Limit 



Camshafts 

Drive system 

Camshaft cap inside diameter 
Camshaft journal diameter 
Camshaft-journal-to-camshaft- 
cap clearance 
Intake camshaft lobe dimensions 



Chain drive (right) 
24.500 ~ 24.521 mm 
24.459 ~ 2AA72 mm 
0.028 ~ 0.062 mm 



••• 
••• 
••• 
••• 




Measurement A 
Measurement B 
Measurement C 
Exhaust camshaft lobe dimensions 



32.5 ~ 32.6 mm 
24.95 ~ 25.05 mm 
7.45 ~ 7.65 mm 



32.4 mm 
24.85 mm 




Measurement A 
Measurement B 
Measurement C 
Max. camshaft runout 



32.95 ~ 33.05 mm 
24.95 - 25.05 mm 
7.75 ~ 7.95 mm 



32.85 mm 
24.85 mm 

••• 

0.03 mm 




2-4 



ENGINE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Timing chain 








Model/number of links 


RH2015/130 




••• 


Tensioning system 


Automatic 




••• 


Valves, valve seats, valve guides 








Valve clearance (cold) 








Intake 


0.11 - 0.20 mm 




••• 


Exhaust 


0.21 - 0.25 mm 




••• 


Valve dimensions 








A 




V \ R 




V | 


/ \ 


A^ VB 




h A H 


\x 


\K 


\ * 


) 


) \ 


) n 








t 

Margin Thickness 


Head Diameter Face Width Seat Width 


Valve head diameter A 








Intake 


22.9 - 23.1 mm 






Exhaust 


24.4 - 24.6 mm 






Valve face width B 








Intake 


1.76 - 2.90 mm 






Exhaust 


1.76 ~ 2.90 mm 






Valve seat width C 








Intake 


0.9 - 1.1 mm 






Exhaust 


0.9 ~ 1.1 mm 






Valve margin thickness D 








Intake 


0.5 ~ 0.9 mm 






Exhaust 


0.5 ~ 0.9 mm 






Valve stem diameter 








Intake 


3.975 ~ 3.990 mm 




3.945 mm 


Exhaust 


4.465 - 4.480 mm 




4.43 mm 


Valve guide inside diameter 








Intake 


4.000 ~ 4.012 mm 




4.05 mm 


Exhaust 


4.500 ~ 4.512 mm 




4.55 mm 


Valve-stem-to-valve-guide clearance 








Intake 


0.010 ~ 0.037 mm 




0.08 mm 


Exhaust 


0.020 ~ 0.047 mm 




0.10 mm 


Valve stem runout 


••• 




0.01 mm 













]_ 


Vj — i V 


, — \^ c 


^ 








I 


r 








-M_l 


///////////////////// 


Valve seat width 








Intake 


0.9 - 1.1 mm 




••• 


Exhaust 


0.9 - 1.1 mm 




••• 



2-5 



ENGINE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Valve springs 






Free length 






Intake 


38.9 mm 


••• 


Exhaust 


40.67 mm 


••• 


Installed length (valve closed) 






Intake 


34.5 mm 


••• 


Exhaust 


35 mm 


••• 


Compressed spring force 






(installed) 






Intake 


82 ~ 96 N (8.36 ~ 9.79 kg) 


••• 


Exhaust 


110 ~ 126 N (11.22 ~ 12.85 kg) 


••• 


Spring tilt 










h— * 






■my////////, 






Intake 


••• 


2.5°/ 
1.7 mm 


Exhaust 


••• 


2.5°/ 
1.8 mm 


Winding direction (top view) 






Intake 


Clockwise 


••• 


Exhaust 


Clockwise 

o 


••• 


Cylinders 






Cylinder arrangement 


Forward-inclined, parallel 4-cylinder 


••• 


Bore x stroke 


74 x 58 mm 


••• 


Compression ratio 


11.4 : 1 


••• 


Bore 


74.00 ~ 74.01 mm 


••• 


Max. taper 


• •• 


0.05 mm 


Max. out-of-round 


• •• 


0.05 mm 



2-6 



ENGINE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Piston 






Piston-to-cylinder clearance 


0.030 ~ 0.055 mm 


0.12 mm 


Diameter D 




73.955 ~ 73.970 mm 


••• 


7 


< 


> 


\ 


H 










/ 




\ / 


/— D 


-^/ ' 


Height H 


5 mm 


••• 


Piston pin bore (in the piston) 






Diameter 


17.002 ~ 17.013 mm 


17.043 


Offset 




• •• 


Offset direction 


Intake side 


• •• 


Piston pins 






Outside diameter 


16.991 ~ 17.000 mm 


16.971 


Piston-pin-to-piston-pin-bore 


0.002 ~ 0.022 mm 


0.072 mm 


clearance 






Piston rings 






Top ring 






Barrel 


• •• 




"N 


) 


B 


T 






Ring type 






Dimensions (B x T) 


0.90 x 2.75 mm 


• •• 


End gap (installed) 


0.32 - 0.44 mm 


• •• 


Ring side clearance 


0.030 ~ 0.065 mm 


• •• 


2nd ring 






Taper 


• •• 




\ 


B 


T 






Ring type 






Dimensions (B x T) 


0.8 x 2.8 


• •• 


End gap (installed) 


0.43 ~ 0.58 mm 


• •• 


Ring side clearance 


0.020 ~ 0.055 mm 


• •• 


Oil ring 






1.5 x 2.6 mm 


• •• 




1 
J 


1 

1 


l 

i 


B 


1 


T 






Dimensions (B x 


T) 




End gap (installed) 


0.10 ~ 0.35 


• •• 



2-7 



ENGINE SPECIFICATIONS 



SPEC 


o- 



Item 



Standard 



Limit 



Connecting rods 

Crankshaft-pin-to-big-end-bearing 

clearance 

Bearing color code 



0.031 ~ 0.055 mm 

-1 = Violet = White 1 = Blue 2 = Black 



Crankshaft 



t 



2 



A 



B 

Width A 
Width B 
Max. runout C 
Big end side clearance D 
Crankshaft-journal-to-crankshaft- 
journal-bearing clearance 
Bearing color code 



52.40 ~ 57.25 mm 
300.75 ~ 302.65 mm 

0.160 ~ 0.262 mm 
0.029 - 0.053 mm 

-1 = Pink/violet = Pink/white 
1 = Pink/blue 2 = Pink/black 
3 = Pink/brown 



••• 

0.03 mm 

••• 
••• 



Clutch 

Clutch type 

Clutch release method 

Clutch release method operation 

Operation 

Clutch cable free play (at the end 

of the clutch lever) 

Friction plates 

Thickness 

Plate quantity 

Thickness 

Plate quantity 
Clutch plates 

Thickness 

Plate quantity 

Max. warpage 
Clutch springs 

Free length 

Spring quantity 



Wet, multiple disc 
Cam (pull rod type) 
Cable operation 
Left-hand operation 
10 - 15 mm 



2.92 ~ 3.08 mm 

8 

3.42 - 3.58 mm 

1 

1.9 - 2.1 mm 

8 

••• 

50 mm 
6 



2.82 mm 



3.32 mm 



••• 
0.1 mm 

••• 
••• 



2-8 



ENGINE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Transmission 

Transmission type 
Primary reduction system 
Primary reduction ratio 
Secondary reduction system 
Secondary reduction ratio 
Operation 
Gear ratios 

1st gear 

2nd gear 

3rd gear 

4nd gear 

5th gear 

6th gear 

Max. main axle runout 
Max. drive axle runout 


Constant mesh, 6-speed 
Spur gear 
68/43(1.581) 
Chain drive 
44/16(2.750) 
Left-foot operation 

35/14(2.500) 

35/19(1.842) 

30/20(1.500) 

28/21 (1.333) 

30/25(1.200) 

29/26(1.115) 

••• 

••• 


0.08 mm 
0.08 mm 


Shifting mechanism 

Shift mechanism type 

Max. shift fork guide bar bending 

Installed shift rod length 


Guide bar 

••• 

260 mm 


••• 

0.1 mm 

••• 


Air filter type 


Dry element 


••• 


Fuel pump 

Pump type 

Model (manufacturer) 

Output pressure 


Electrical 

4SV (MITSUBISHI) 

20 kPa (0.2 kg/cm 2 ) 


••• 
••• 
••• 



2-9 



ENGINE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Carburetors 

Model (manufacturer) x quantity 
Throttle cable free play (at the 
flange of the throttle grip) 
ID mark 
Main jet 

Main air jet 
Jet needle 

Needle jet 

Pilot air jet 

Pilot outlet 

Pilot jet 

Bypass 1 

Bypass 2 

Bypass 3 

Pilot screw turns out 

Valve seat size 

Starter jet 1 

Starter jet 2 

Throttle valve size 

Fuel level (above the line on the 

float chamber) 


BSR37 (MIKUNI) x 4 
3 — 5 mm 

5LV1 00 

Carburetors 1 and 4: #132.5 

Carburetors 2 and 3: #130 

#80 

Carburetor 1 and 4: 5D1 29-3/5 

Carburetor 2 and 3: 5D1 30-3/5 

P-OM 

#85 

1.0 

#15 

0.9 

0.9 

0.9 

2.0 

1.5 

#42.5 

0.8 

#115 

3.0 - 4.0 mm 




Max. EXUP cable free play (at the 
EXUP valve pulley) 


1.5 mm 


••• 



2-10 



CHASSIS SPECIFICATIONS 



SPEC 


o- 



CHASSIS SPECIFICATIONS 



Item 


Standard 


Limit 


Frame 






Frame type 


Double cradle 


••• 


Caster angle 


26° 


••• 


Trail 


104 mm 


••• 


Front wheel 






Wheel type 


Cast wheel 


••• 


Rim 






Size 


17 x MT3.50 


••• 


Material 


Aluminum 


••• 


Wheel travel 


140 mm 


••• 


Wheel runout 






Max. radial wheel runout 


••• 


1 mm 


Max. lateral wheel runout 


••• 


0.5 mm 


Rear wheel 






Wheel type 


Cast wheel 


••• 


Rim 






Size 


17 x MT5.50 


••• 


Material 


Aluminum 


••• 


Wheel travel 


135 mm 


••• 


Wheel runout 






Max. radial wheel runout 


••• 


1 mm 


Max. lateral wheel runout 


••• 


0.5 mm 


Front tire 






Tire type 


Tube I ess 


••• 


Size 


120/70 ZR1 7 (58W) 


••• 


Model (manufacturer) 


MEZ4Y FRONT (METZELER) 
BT020F U (BRIDGESTONE) 


••• 


Tire pressure (cold) 






~ 90 kg 


250 kPa (2.5 kgf/cm 2 , 2.5 bar) 


••• 


90 ~ 201 kg 


250 kPa (2.5 kgf/cm 2 , 2.5 bar) 


••• 


High-speed riding 


250 kPa (2.5 kgf/cm 2 , 2.5 bar) 


••• 


Min. tire tread depth 


• •• 


1.6 mm 



2-11 



CHASSIS SPECIFICATIONS 




Item 


Standard 


Limit 


Rear tire 






Tire type 

Size 

Model (manufacturer) 

Tire pressure (cold) 
~ 90 kg 
90 ~ 201 kg 
High-speed riding 

Min. tire tread depth 


Tubeless 

180/55 ZR1 7 (73W) 
MEZ4Y (METZELER) 
BT020R U (BRIDGESTONE) 

270 kPa (2.7 kgf/cm 2 , 2.7 bar) 
290 kPa (2.9 kgf/cm 2 , 2.9 bar) 
290 kPa (2.9 kgf/cm 2 , 2.9 bar) 

••• 


••• 
••• 
••• 

••• 
••• 
••• 
1.6 mm 


Front brakes 






Brake type 
Operation 
Recommended fluid 


Dual-disc brake 
Right-hand-operation 
DOT 4 


••• 
••• 
••• 


Brake discs 






Diameter x thickness 


298 x 5 mm 


••• 


Min. thickness 


••• 


4.5 mm 


Max. deflection 


••• 


0.1 mm 


Brake pad lining thickness 


5.5 mm 


0.5 mm 


\m- U- ':::: I 


K™"™"^* 


Master cylinder inside diameter 
Caliper cylinder inside diameter 


14 mm 

30.2 mm and 27 mm 


••• 
••• 


Rear brake 






Brake type 

Operation 

Brake pedal position (from the top 

of the brake pedal to the top of the 

rider footrest) 

Recommended fluid 


Single-disc brake 
Right-foot operation 
35 ~ 40 mm 

DOT 4 


••• 
••• 
••• 

••• 


Brake discs 






Diameter x thickness 


267 x 5 mm 


••• 


Min. thickness 


••• 


4.5 mm 


Max. deflection 


••• 


0.1 mm 


Brake pad lining thickness 


5.5 mm 


0.5 mm 


&-.}. •.'•.. '.' | 


^^^^^_^* 


Master cylinder inside diameter 
Caliper cylinder inside diameter 


12.7 mm 
42.9 mm 


••• 
••• 



2-12 



CHASSIS SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Front suspension 






Suspension type 


Telescopic fork 




Front fork type 


Coil spring/oil damper 




Front fork travel 


140 mm 




Spring 






Free length 


344.0 mm 




Spacer length 


78.5 mm 




Installed length 


320.0 mm 




Spring rate (K1) 


8.1 N/mm (0.83 kg/mm) 




Spring rate (K2) 


11.8 N/mm (1.2 kg/mm) 




Spring stroke (K1) 


— 55 mm 




Spring stroke (K2) 


55 — 140 mm 




Optional spring available 


No 




Fork oil 






Recommended oil 


Suspension oil "01" or equivalent 




Quantity (each front fork leg) 


440 cm 3 




Level (from the top of the inner 


140 mm 




tube, with the inner tube fully 






compressed, and without the 






fork spring) 






Spring preload adjusting positions 






Minimum 


5 (fully turned out position) 


••• 


Standard 


2 


••• 


Maximum 


1 


••• 


Rebound damping adjusting 






positions 






Minimum* 


17 


••• 


Standard* 


7 


••• 


Maximum* 


1 


••• 


Compression damping adjusting 






positions 






Minimum* 


21 


••• 


Standard* 


6 


••• 


Maximum* 


1 


••• 


*from the fully turned-in position 







2-13 



CHASSIS SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Steering 

Steering bearing type 


Angular ball bearings 


••• 


Rear suspension 

Suspension type 

Rear shock absorber assembly 

type 

Rear shock absorber assembly 

travel 

Spring 

Free length 

Installed length 

Spring rate (K1) 

Spring stroke (K1) 
Optional spring available 
Standard spring preload gas/air 
pressure 
Spring preload adjusting positions 

Minimum 

Standard 

Maximum 

Rebound damping adjusting 
positions 

Minimum* 

Standard* 

Maximum* 
Compression damping adjusting 
positions 

Minimum* 

Standard* 

Maximum* 
*from the fully turned-in position 


Swingarm (link suspension) 
Coil spring/gas-oil damper 

65 mm 

182.5 mm 

163 mm 

73.6 N/mm (7.5 kgf/mm) 

- 65 mm 

No 

1,200kPa(12kgf/cm 2 ) 

1 
6 
11 

20 
10 
3 

1 
7 
12 


••• 
••• 

••• 

••• 
••• 
••• 
••• 
••• 
••• 

••• 
••• 
••• 

••• 
••• 
••• 

••• 
••• 
••• 


Swingarm 

Free play (at the end of the 
swingarm) 

Radial 

Axial 


••• 
••• 


1 mm 
1 mm 


Drive chain 

Model (manufacturer) 
Link quantity 
Drive chain slack 
Maximum ten-link section 


50ZVM (DAIDO) 

116 

40 - 50 mm 

150.1 mm 


••• 
••• 
••• 
152.5 mm 



2-14 



ELECTRICAL SPECIFICATIONS 



SPEC 


o- 



ELECTRICAL SPECIFICATIONS 



Item 


Standard 


Limit 


System voltage 


12V 


••• 


Ignition system 

Ignition system type 

Ignition timing 

Advanced timing 

Advancer type 

Pickup coil resistance/color 

Transistorized coil ignition unit 

model (manufacturer) 


Transistorized coil ignition 

5° BTDC at 1,100 r/min 

55° BTDC at 5,000 r/min 

Throttle position sensor and electrical 

248 ~ 372 Q/Gy-B 

TNDF66 (DENSO) 




Ignition coils 

Model (manufacturer) 
Minimum ignition spark gap 
Primary coil resistance 
Secondary coil resistance 


J0313(DENSO) 
6 mm 

1.87 ~ 2.53 ft 
12 ~ 18kft 




Spark plug caps 

Material 
Resistance 


Rubber 
10 ka 




Throttle position sensor standard 
resistance 


4 ~ 6kft 




Charging system 

System type 

Model (manufacturer) 

Normal output 

Stator coil resistance/color 


AC magneto 
F4T361 (MITSUBISHI) 
14 V/365 Wat 5,000 r/min 
0.27 ~ 0.33ftat20°C/W-W 




Rectifier/regulator 

Regulator type 
Model (manufacture) 
No-load regulated voltage 
Rectifier capacity 
Withstand voltage 


Semiconductor short circuit 
SH650C-11 (SHINDENGEN) 
14.1 ~ 14.9 V 
18A 
200 V 




Battery 

Battery type 

Battery voltage/capacity 


GT14B-4 
12V/12AH 




Headlight type 


Halogen bulb 




Bulbs (voltage/wattage x quantity) 

Headlight 
Auxiliary light 
Tail/brake light 
Turn signal light 
Meter light 


12V60W/55W x 2 
12V5W x 2 
12V5W/21 W x 2 
12V21 W x 4 
12 V2W x 3 





2-15 



ELECTRICAL SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Indicator light 
(voltage/wattage x quantity) 

Neutral indicator light 

High beam indicator light 

Oil level indicator light 

Turn signal indicator light 

Fuel indicator light 

Water temperature indicator light 


14V1.4W x 1 
14V1.4W x 1 
14V1.4W x 1 
14V1.4W x 2 
12V2W x 1 
LED 


••• 
••• 
••• 
••• 
••• 
••• 


Electric starting system 

System type 
Starter motor 

Model (manufacturer) 

Power output 

Brushes 
Overall length 
Spring force 

Commutator resistance 

Commutator diameter 

Mica undercut 


Constant mesh 

SM-13(MITSUBA) 
0.8 kW 

12.5 mm 

7.65 ~ 10.01 N(780 ~ 1,021 gf) 

0.025 ~ 0.035 ft 

28 mm 

0.7 mm 


••• 

••• 
••• 

4 mm 

••• 
••• 

27 mm 

••• 


Starter relay 

Model (manufacturer) 

Amperage 

Coil resistance 


MS5F-631 (JIDECO) 

180 A 

4.18 ~ 4.62 ft 


••• 
••• 
••• 


Horn 

Horn type 

Model (manufacturer) x quantity 

Max. amperage 


Plain 

YF-12(NIKKO) x 1 
3A 


••• 
••• 
••• 


Turn signal relay 

Relay type 

Model (manufacturer) 

Self-cancelling device built-in 

Turn signal blinking frequency 

Wattage 


Full-transistor 

FE246BH (DENSO) 

No 

75 - 95 cycles/min. 

21 W x 2 + 3.4 W 


••• 
••• 
••• 
••• 
••• 


Oil level switch 

Model (manufacturer) 


5LV (DENSO) 


••• 


Fuel sender 

Model (manufacturer) 
Resistance 


5LV (NIPPON SEIKI) 
4 ~ 100ftat25°C 


••• 
••• 


Sidestand/fuel pump relay 

Model (manufacturer) 
Coil resistance 


5EB-20 (OMRON) 
180 ft 


••• 
••• 


Fuel pump maximum amperage 


1.2 A 


••• 


Radiator fan 

Model (manufacturer) 


4XV (TOYO RADIATOR) 


••• 


Thermo switch 

Model (manufacturer) 


5JJ (NIPPON THERMOSTAT) 


••• 



2-16 



ELECTRICAL SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Fuses (amperage x quantity) 






Main fuse 


30 A x 1 




Headlight fuse 


20 A x 1 




Signaling system fuse 


20 A x 1 




Ignition fuse 


20 A x 1 




Radiator fan fuse 


10A x 1 




Turn signal relay fuse 


10A x 1 




Backup fuse (odometer) 


10A x 1 




Reserve fuse 


30 A x 1 
20 A x 1 
10A x 1 





2-17 



TIGHTENING TORQUES 



SPEC 


o- 



TIGHTENING TORQUE 

GENERAL TIGHTENING TORQUES 

This chart specifies tightening torques for stan- 
dard fasteners with a standard ISO thread pitch. 
Tightening torque specifications for special 
components or assemblies are provided for 
each chapter of this manual. To avoid warpage, 
tighten multi-fastener assemblies in a criss- 
cross pattern and progressive stages until the 
specified tightening torque is reached. Unless 
otherwise specified, tightening torque specifi- 
cations require clean, dry threads. Compo- 
nents should be at room temperature. 




A: Distance between flats 
B: Outside thread diameter 



A 

(Nut) 


B 

(Bolt) 


General t 
torq 


ightening 
ues 


Nm 


m»kg 


10 mm 


6 mm 


6 


0.6 


12 mm 


8 mm 


15 


1.5 


14 mm 


10 mm 


30 


3.0 


17 mm 


12 mm 


55 


5.5 


19 mm 


14 mm 


85 


8.5 


22 mm 


16 mm 


130 


13.0 



2-18 



TIGHTENING TORQUES 



SPEC 


o- 



ENGINE TIGHTENING TORQUES 











Tightening 




Item 


Fastener 


Thread 
size 


Q'ty 


tore 


iue 


Remarks 


Nm 


m«kgf 


Spark plugs 


- 


M10 


4 


13 


1.3 




Cylinder head 


Nut 


M10 


8 


50 


5.0 


^*0 


Cylinder head 


Cap nut 


M10 


2 


50 


5.0 


— Q 


Cylinder head 


Bolt 


M6 


2 


12 


1.2 




Camshaft caps 


Bolt 


M6 


28 


10 


1.0 


— Q 


Cylinder head cover 


Bolt 


M6 


6 


12 


1.2 




Cylinder head (exhaust pipe) 


Stud bolt 


M8 


8 


15 


1.5 


^-Hl^j 


Connecting rod caps 


Nut 


M8 


8 


36 


3.6 


■1§^| 


Generator rotor 


Bolt 


M10 




65 + 60° 


6.5 + 60° 


^-Hl^j 


Crankshaft sprocket 


Bolt 


M10 




60 


6.0 


^-Hl^j 


Cap bolt (timing chain tensioner) 


Bolt 


M6 




6.4 


0.64 




Camshaft sprocket 


Bolt 


M7 


4 


24 


2.4 




Water pump inlet pipe 


Bolt 


M6 




10 


1.0 


nca 


Water pump outlet pipe 


Bolt 


M6 




10 


1.0 


nca 


Oil/water pump assembly driven 
sprocket 


Bolt 


M6 




15 


1.5 


nca 


Oil pump 


Bolt 


M6 




12 


1.2 




Oil cooler 


Bolt 


M20 




35 


3.5 


^*0 


Engine oil drain bolt 


- 


M14 




43 


4.3 




Oil strainer housing 


Bolt 


M6 


2 


10 


1.0 


nca 


Oil/water pump assembly driven 


Bolt 


M6 




12 


1.2 


nca 


sprocket cover 














Oil delivery pipe 


Bolt 


M6 




10 


1.0 


nca 


Oil filter bolt 


Bolt 


M20 




70 


7.0 




Oil filter cartridge 


- 


M20 




17 


1.7 


^•Gi 


Oil pipe 


Bolt 


M6 


2 


10 


1.0 




Air cleaner cap and air cleaner 


Screw 


M6 


4 


6 


0.6 




Frame and air cleaner 


Bolt 


M6 


3 


7 


0.7 




Air cleaner cover and air cleaner 


Screw 


M6 


6 


2 


0.2 




Ring nut and cylinder head 


Nut 


M8 


8 


20 


2.0 




Exhaust pipe and muffler 


Bolt 


M8 


3 


20 


2.0 




Emission check bolt 


Bolt 


M8 


4 


10 


1.0 




EXUP pulley cover 


Bolt 


M6 


3 


10 


1.0 


Hca 


EXUP cable bracket 


Bolt 


M6 


3 


10 


1.0 




EXUP pulley and shaft arm 


Bolt 


M5 


1 


10 


1.0 




Exhaust joint 


Bolt 


M4 


2 


3 


0.3 




Exhaust pipe assembly 


Bolt 


M8 


1 


20 


2.0 




Air induction system pipe 


Band 


- 


4 


3.5 


0.35 


— Q 


Crankcase (cylinder head) 


Stud bolt 


M10 


10 


10 


1.0 


— Hi^j 


Crankcase 


Bolt 


M9 


10 


See 


note 


^-Hl^j 


Crankcase 


Bolt 


M6 


2 


14 


1.4 


^-Hl^j 


Crankcase 


Bolt 


M6 


14 


12 


1.2 


^-Hl^j 


Crankcase 


Bolt 


M8 


2 


24 


2.4 





2-19 



TIGHTENING TORQUES 



SPEC 


o- 



Item 


Fastener 


Thread 
size 


Q'ty 


Tightening 
torque 


Remarks 














Nm 


m«kgf 




AC magneto cover 


Bolt 


M6 


9 


12 


1.2 




Drive sprocker cover 


Bolt 


M6 


4 


10 


1.0 




Plate 


Bolt 


M6 


2 


10 


1.0 




Clutch cover 


Bolt 


M6 


8 


12 


1.2 




Timing chain cap bolt 


Bolt 


M6 


8 


12 


1.2 




Shift shaft cover 


Bolt 


M6 


5 


12 


1.2 




Breather plate 


Bolt 


M6 


5 


10 


1.0 




Timing mark accessing screw 


Bolt 


M8 


1 


15 


1.5 




Starter clutch idle gear shaft 


Bolt 


M6 


1 


10 


1.0 




Starter one-way clutch 


Bolt 


M6 


3 


12 


1.2 




Clutch boss 


Nut 


M20 


1 


90 


9.0 


Use a lock 
washer. 


Clutch spring 


Bolt 


M6 


6 


8 


0.8 




Drive sprocket 


Nut 


M22 


1 


85 


8.5 


Use a lock 
washer. 


Main axle bearing housing 


Screw 


M6 


3 


12 


1.2 




Shift lever stopper 


Bolt 


M6 


2 


10 


1.0 




Stopper screw 


Screw 


M8 


1 


22 


2.2 




Shift rod 


Nut 


M6 


1 


6.5 


0.65 


Left thread 


Shift rod 


Nut 


M6 


2 


6.5 


0.65 




Shift rod joint 


Bolt 


M6 


1 


10 


1.0 




Shift arm 


Bolt 


M6 


1 


10 


1.0 




AC magneto stator coil 


Screw 


M6 


3 


14 


1.4 




Ignitor unit 


Screw 


M5 


2 


7 


0.7 




Neutral switch 


- 


M10 


1 


20 


2.0 




Pick up coil 


Bolt 


M6 


2 


10 


1.0 




Thermo unit 


- 


- 


1 


15 


1.5 





NOTE: 

1 . First, tighten the bolt to approximately 14.7 Nm (1 .5 m»kg) with a torque wrench. 

2. Retighten the bolt to 14.7 Nm (1 .5 nrkg), and tighten another 45 ~ 50°. 



2-20 



TIGHTENING TORQUES 



SPEC 


o- 



Crankcase tightening sequence: 




2-21 



TIGHTENING TORQUES 



SPEC 


o- 



CHASSIS TIGHTENING TORQUES 



Item 


Thread size 


Tightening 


Remarks 


Nm 


m»kgf 


Upper bracket pinch bolt 


M8 


30 


3.0 




Upper bracket cap nut 


M22 


110 


11 




Upper bracket and handlebar holder 


M10 


32 


3.2 




Handlebar holder 


M8 


23 


2.3 




Lower bracket pinch bolt 


- 


23 


2.3 




Lower bracket ring nut 


M25 


18 


1.8 


See note 


Front brake master cylinder 


M6 


10 


10 




Front brake hose union bolt 


M10 


30 


3.0 




Engine mounting 










Engine mounting bolt/nut 


M10 


55 


5.5 




Engine mounting bolt/nut 


M8 


33 


3.3 




Frame and down tube 


M10 


89 


8.9 




Clutch cable lock nut 


M8 


7 


0.7 




Ignition coil and stay 


M6 


7 


0.7 




Pivot shaft 


M18 


125 


12.5 




Rear shock absorber (upper) 


M10 


40 


4.0 




Rear shock absorber and relay arm 


M10 


40 


4.0 




Relay arm and frame 


M10 


40 


4.0 




Relay arm and connecting arm 


M12 


48 


4.8 




Connecting arm and swing arm 


M12 


48 


4.8 




Drive chain guard 


M6 


7 


0.7 




Drive chain case 


M6 


7 


0.7 




Fuel cock 


M6 


7 


0.7 




Fuel sender 


M5 


4 


0.4 




Side cover 


M6 


4 


0.4 




Coolant reservoir tank 


M6 


4 


0.4 




Front wheel axle 


M16 


72 


7.2 




Front wheel axle pinch bolt 


M8 


23 


2.3 




Front brake caliper 


M10 


40 


4.0 




Front brake disk 


M6 


18 


1.8 


-C3 


Front brake bleed screw 


M8 


6 


0.6 




Rear brake torque rod 


M8 


23 


2.3 




Rear wheel sprocket 


M10 


69 


6.9 




Drive chain adjusting nut 


M8 


16 


1.6 




Rear brake caliper 


M10 


40 


4.0 




Rear wheel axle 


M24 


150 


15 




Rear brake hose union bolt 


M10 


30 


3.0 




Rear brake bleed screw 


M8 


6 


0.6 




Rear brake disk 


M8 


23 


2.3 


-d 


Rider footrest bracket and frame 


M8 


30 


3.0 




Rear brake reservoir tank 


M6 


4 


0.4 




Rear brake master cylinder 


M8 


23 


2.3 




Rider footrest and bracket 


M10 


55 


5.5 




Passenger footrest bracket and frame 


M8 


28 


2.8 




Passenger footrest bracket and muffler 


M10 


48 


4.8 





NOTE: 

1 . First, tighten the ring nut to approximately 52 Nm (5.2 m«kg) with a torque wrench, then loosen the 
ring nut completely. 

2. Retighten the ring nut to specification. 

2^22 



LUBRICATION POINTS AND LUBRICANT TYPES 



SPEC 


o- 



LUBRICATION POINTS AND LUBRICANT TYPES 

ENGINE 



Lubrication point 


Lubricant 


Oil seal lips 


H@M 


O-rings 


«fl@M| 


Bearings 


^Q 


Crankshaft pins 


-a 


Piston surfaces 


-a 


Piston pins 


-a 


Connecting rod bolts and nuts 


-Ȥ*i 


Crankshaft journals 


-CI 


Camshaft lobes 


— <g 


Camshaft journals 


— d 


Valve stems (intake and exhaust) 


— @ 


Valve stem ends (intake and exhaust) 


-a 


Water pump impeller shaft 


^Q 


Oil pump rotors (inner and outer) 


-Q 


Oil strainer 


-a 


Starter clutch idle gear inner surface 


-a 


Starter clutch assembly 


-Q 


Primary driven gear 


-a 


Transmission gears (wheel and pinion) 


— ^g 


Main axle and drive axle 


— <jj 


Shift drum 


-Q 


Shift forks and shift fork guide bars 


-a 


Shift shaft 


-a 


Shift shaft boss 


■^§»t 


Cylinder head cover mating surface 


Yamaha bond 
No.1215 


Crankcase mating surface 


Yamaha bond 
No.1215 


Clutch cover (crankcase mating surface) 


Yamaha bond 
No.1215 


Generator rotor cover (crankcase mating surface) 


Yamaha bond 
No.1215 



2-23 



LUBRICATION POINTS AND LUBRICANT TYPES 



SPEC 


o- 



EAS00032 

CHASSIS 



Lubrication point 


Lubricant 


Steering bearings, steering seal lips and ball race cover lips 


^§H 


Pivot shaft 


*^®ML 


Swing arm pivoting points and connecting arm bearings 


h^lsM| 


Connecting arm oil seal lips 


■"ffL§M| 


Swing arm oil seal lips 


*Ht-sJM^ 


Relay arm bearings 


*^@B4 


Relay arm oil seal lips 


h^lsM^ 


Rear shock absorber upper bolt 


^|lsJM^ 


Front wheel oil seal lips 


l H^sPH| 


Rear wheel oil seal lips 


■"•©W^ 


Clutch hub oil seal lips 


H^sM 


Throttle cable end 


"H^sPH| 


Starter cable end and starter lever 


h^lsM^ 


Rear brake pedal moving point 


^§M 


Shift pedal moving point 


^sM 


Side stand moving point 


™^LS^* 


Passenger footrest ball joint and moving point 


H^sM 


Engine mounting bracket collar and oil seal lips 


— C- S ^l 


Mainstand moving point 


■H^^H| 



2-24 



COOLING SYSTEM DIAGRAMS 



SPEC 


o- 



COOLING SYSTEM DIAGRAMS 

® Radiator cap 

(2) Thermostat housing 

(3) Radiator 
Water pump 




2-25 



® Radiator cap 

(2) Thermostat housing 

(3) Radiator 
® Oil cooler 

(5) Water jacket joint 



COOLING SYSTEM DIAGRAMS 



SPEC 


o- 




2-26 



® Radiator cap 

(2) Thermostat 

(3) Thermo unit 



COOLING SYSTEM DIAGRAMS 



SPEC 


o- 




2-27 



© Radiator 



COOLING SYSTEM DIAGRAMS 



SPEC 


o- 




2-28 



ENGINE OIL LUBRICATION CHART 



SPEC 


o- 



ENGINE OIL LUBRICATION CHART 



Strainer 



Exhaust 
camshaft 



Intake 

camshaft | , , 1 1~^ 



IT 



IT 




T 



Main gallery 



Oil filter 



Relief 
valve 



Oil 
cooler 



T 




Main axle 



Drive axle 



2-29 



LUBRICATION DIAGRAMS 



EAS00034 

LUBRICATION DIAGRAMS 

® Oil cooler 

(2) Oil filter cartridge 

(3) Drain bolt 

Oil level switch 

(5) Oil strainer 

(6) Oil pump 



SPEC 


o- 




2-30 



® Intake camshaft 

(2) Exhaust camshaft 

(3) Oil cooler 
® Oil strainer 
(5) Oil pump 



LUBRICATION DIAGRAMS 



SPEC 


o- 




2-31 



® Intake camshaft 

(2) Exhaust camsahft 

(3) Oil filter cartridge 
® Oil level switch 



LUBRICATION DIAGRAMS 



SPEC 


o- 




2-32 



® Cylinder head 
(2) Crankshaft 



LUBRICATION DIAGRAMS 



SPEC 


o- 




2-33 



® Main axle 

(2) Oil delivery pipe 

(3) Drive axle 



LUBRICATION DIAGRAMS 



SPEC 


o- 








2-34 



CABLE ROUTING 



SPEC 


o- 



CABLE ROUTING 

[A] Fasten the handlebar switch lead (right) and han- 
dlebar with a plastic band. 

\B\ Route the handlebar switch lead (right) backward 
the throttle cable and right side the brake hose 
guide. 

\C\ Fasten the handlebar switch lead (left) and handle- 
bar with aplastic band. 

\D\ Fasten the handlebar switch lead (left), main switch 
lead, clutch cable and starter cable with a plastic 
band. Clamp beneath the horn lead branching posi- 
tion. Do not fasten the horn lead. 

[E] Route the main switch lead front and left side the 
another leads. 



\F\ Route the horn lead outside the motorcycle body, 
and fasten with the under bracket. Do not loose be- 
tween the horn and under bracket. 

[G| Route the brake hose through the brake hose 
guide. 

[R] Route the throttle cable 1 and 2 backward the brake 
hose, and left side the brake hose guide. 




2-35 



CABLE ROUTING 



SPEC 


o- 



© Fuel pump lead 

® Fuel pump 

© EXUP cable 

© Handlebar switch lead (right) 

® Throttle cable 1 

® Throttle cable 2 

© Water-carburetor hose 

® Fan motor lead 

© Coolant reservoir tank over flow 

hose 
© Fuel tank drain hose 
© Fuel tank breather hose 
©White paint mark 
© Rear brake light switch lead 
© Neutral switch lead 
© Speedo sensor lead 
@ Pickup coil lead 



© Handle crown 

@ Handlebar switch lead 

© Brake hose guide 



m 



® 

m 
m 
m 
e 



Fasten the fuel pump lead, pickup coil lead, neutral switch lead, speed 

sensor lead, rear brake light switch lead and fuel pump with a plastic 

clamp. 

Fasten the fuel hose, pickup coil lead, neutral switch lead and speed 

sensor lead with a plastic clamp under the fuel hose. 

Put the EXUP cable into the air box cover. 

Route the T.P.S. lead inward the EXUP cable. 

Fasten the water-carburetor hose with a plastic band. 

Route the coolant hose over the frame. 

Fasten the handlebar switch lead and frame with a plastic guide. 

Align the white tape mark of the handlebar switch lead (right) with the 

tank rail welding bead and clamp down throttle cables 1 and 2. 




2-36 



CABLE ROUTING 



SPEC 


o- 



\T\ Route the water-carburetor hose between the [Q] 
frame cross pipe and fan motor lead. [R] 

[J] To the carburetor 

El Fasten the T.P.S. lead with a steel clamp. \S\ 

{L\ Fasten the coolant hose with a plastic band. 

M Fasten the pickup coil lead with a steel clamp. \J\ 

\E\ Pass the coolant reservoir tank overflow hose, fuel 
tank drain hose and fuel tank breather hose through \U\ 
the frame hose holder from the inside of the vehicle 
to the outside. At this time, pull the fuel tank drain \W\ 
hose and fuel tank breather hose so that the white 
paint marks are within a 20 mm range. 

[O] Route the EXUP cable forward the another hoses, [X] 
and upward the engine mounting bracket. 

[0 Fasten the rear brake light switch lead with a plastic [Y] 
guide. 



Insert the all couplers into the rubber cover. 
Route the rear brake light switch lead inside the 
another leads. 

Route the neutral switch lead and speed sensor 
lead left side the coolant reservoir hose. 
Route the coolant reservoir hose left side the en- 
gine mounting bracket. 

Route the coolant reservoir hose forward the neu- 
tral switch lead and speed sensor lead. 
Route the coolant reservoir hose backward the 
another hoses. 

Route the EXUP cable forward the another hoses. 
Route the EXUP cable forward the frame cross 
pipe. 

Route the fuel tank drain hose and fuel tank breath- 
er hose forward the neutral switch lead and speed 
sensor lead. 




2-37 



CABLE ROUTING 



SPEC 


o- 



© Starter cable 

© Clutch cable 

© Handlebar switch lead (left) 

Main switch lead 

(§) EXUP servo motor 

® Starting circuit cutoff relay 

© Starter motor lead 

® Fan motor relay 

© Air cleaner case drain hose 

© Sidestand switch lead 

@ oil level switch lead 

© ACgenerator lead 

© Water-head pipe 

@ Water-carburetor hose 

© Throttle cable 2 

© Throttle cable 1 

<yh EXUP cable 



IS 



m 
m 
m 

E 

m 
e 
m 

lei 

E 

[Ml 



Fasten the main switch lead and handlebar switch lead with a plastic 

guide. 

Fasten the water-head hose and water-carburetor hose with a plastic 

band. 

Fasten the clutch cable with a plastic band. 

Fasten the clutch cable with a steel clamp. 

Fasten the wire harness with a plastic band. 

To the fuel sender. 

Route the fuel sender lead inside the seat rail. 

Route the battery negative lead forward the frame stay. 

Route the main harness inside the rear fender groove. 

Fasten the wire harness, sidestand switch lead, oil level switch and 

flame with a plastic band. Do not fasten the Acgenerator lead (white). 

Route the starter motor lead and battery negative lead inside the plastic 

band. 

Route the all hoses outside the fuel hose. 

Route the fuel hose through the steel guide. 




2-38 



CABLE ROUTING 



SPEC 


o- 



\E\ Fasten the sidestand switch lead, oil level switch lead, 

ACgenerator lead, starter motor lead, battery negative 

lead and air cleaner case drain hose with a plastic clamp. 
[Ol Fasten the sidestand switch lead, oil level switch lead, 

ACgenerator lead and air filter case drain hose with a 

plastic clamp. 
[P] Fasten the sidestand switch lead and frame with a plastic 

clamp. 
[Ol Route the air cleaner box drain hose inside the sidestand 

switch lead, and put the end of the hose backward. 
[r] Fasten the sidestand switch lead and frame with a plastic 

clamp. 
[S] Fasten the sidestand switch lead, oil level switch lead and 

air filter case drain hose with a plastic clamp. Do not crush 

the air filter case drain hose. 
\T\ Route the high tension cable (#1 ) outside the starter cable 

and water-carburetor hose, and under the clutch cable 



and rectifier regulator lead. 

Qj] Route the water carburetor hose outside the coolant 
hose. 

[VI Route the starter cable outside the coolant hose, and up- 
per the water-carburetor hose. 

M Route the high tension cable (#2, 3) forward the EXUP 
cable and high tension cable (#4). 

[X] Route the throttle cable between the water-head hose, 
and upper the EXUP cable. 

[Y] Route the high tension cable (#4) between the water- 
head hose. 

\z\ Tail light lead and flasher light lead (right) should not be 
stick out from the gap between the rear fender and tail- 
light. 

[AA| Route the flasher light lead through the hole on the rear 
fender. 

|AB| Route the wire harness in the groove. 




2-39 



CABLE ROUTING 



SPEC 


o- 



© Clutch cable 

© Handlebar switch lead 

© Main switch lead 

Starter cable 

® Thermo unit lead 

® Throttle cable 1 

© Throttle cable 2 

® Handlebar switch lead (right) 

© Coolant reservoir hose 

© Ignition coil 

© Fuel hose 

© Fan motor lead 

© EXUP servo motor lead 

@ Rectifier/regulator lead 

©White paint mark 

© Main harness 



© 

© 
© 

© 



Ignition coil lead 

Battery 

Emergency engine stop switch 

Flasher relay 

Fuse box 

Igniter unit 

Flasher light lead 

Taillight lead 

Alarm coupler (free) 

Starter relay 

Battery positive lead 

Fan motor lead 

Battery negative lead 

Starting circuit cutoff relay 




2-40 



CABLE ROUTING 



SPEC 


o- 













Fasten the flasher light lead and headlight lead with [K] 
a plastic clamp. 

Route the rectifier/regulator lead upper the fan mo- {L\ 
tor lead and EXUP servomotor lead. 
Route the throttle cable right side the fan motor [M] 
lead, EXUP servo motor lead and thermo unit lead. [N] 
Fasten the flasher light lead with a plastic clamp. 
Route the all leads between the frame cross pipe [O] 
and bracket. 

Do not excessively bend the throttle cable. \P\ 

Route the coolant reservoir hose under the frame 
cross pipe. [Q] 

Fasten the ignition coil and ignition coil lead with a [R] 
plastic clamp. \S\ 

Route the T.P.S. lead under the air vent hose. 
Fasten the EXUP cable with a plastic band. 



Fasten the fuel hose and air induction system hose 

with a plastic clamp. 

Route the coolant reservoir hose under the frame 

cross pipe. 

Fasten the fuel hose and frame with a plastic band. 

Put the fuel tank drain hose into the frontward nipple 

on the fuel tank. 

Put the fuel tank breather hose into the backward 

nipple on the fuel tank. 

Route the coolant reservoir hose under the air vent 

hose and air induction system hose. 

Route the air vent hose upper the main harness. 

All coupler into the rubber cover. 

Fasten the Rectifier/regulator lead with a plastic 

band in the main harness. 




2-41 



CABLE ROUTING 



SPEC 


o- 



\T\ Fasten the ignition coil lead and frame cross pipe |AA] Put the seat lock cable into the groove on the rear 



with a plastic clamp. Do not fasten the red/black 
lead and orange lead. 

\U\ Fasten the handlebar switch lead (left/right), main 
switch lead, EXUP servo motor lead, fan motor lead 
and thermo unit lead with a plastic clamp. 

[V] Fasten the rectifier/regulator stay and rectifier/ reg- 
ulator lead with a plastic clamp. 

Route the wire harness under the rectifier/ regula- 
tor. 

[X] Fasten the battery negative lead with a battery 
band. 

\Y\ Insert the ground lead coupler in the battery band. 

\7\ Fasten the taillight lead and flasher light lead, and 
put in the groove on the taillight bracket. 



fender. 
[ABl Fasten the battery positive lead with a plastic band. 




2-42 



CHK 
ADJ 


<a 



CHAPTER 3 
PERIODIC CHECKS AND ADJUSTMENTS 

INTRODUCTION 3-1 

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-1 

FRONT COWLING/SEAT/SIDE COVER/FUEL TANK 3-3 

FRONT COWLING 3-3 

SEAT, SIDE COVER AND FUEL TANK 3-4 

ENGINE 3-5 

ADJUSTING THE VALVE CLEARANCE 3-5 

SYNCHRONIZING THE CARBURETORS 3-10 

ADJUSTING THE ENGINE IDLING SPEED 3-12 

ADJUSTING THE THROTTLE CABLE FREE PLAY 3-13 

CHECKING THE SPARK PLUGS 3-15 

CHECKING THE IGNITION TIMING 3-16 

MEASURING THE COMPRESSION PRESSURE 3-17 

CHECKING THE ENGINE OIL LEVEL 3-19 

CHANGING THE ENGINE OIL 3-20 

ADJUSTING THE CLUTCH CABLE FREE PLAY 3-22 

CLEANING THE AIR FILTER ELEMENT 3-23 

CHECKING THE CARBURETOR JOINTS AND 

INTAKE MANIFOLDS 3-24 

CHECKING THE FUEL HOSES AND FUEL FILTER 3-24 

CHECKING THE CRANKCASE BREATHER HOSE 3-25 

CHECKING THE EXHAUST SYSTEM 3-25 

ADJUSTING THE EXUP CABLES 3-26 

CHECKING THE COOLANT LEVEL 3-27 

CHECKING THE COOLING SYSTEM 3-29 

CHANGING THE COOLANT 3-30 

CHASSIS 3-33 

ADJUSTING THE FRONT BRAKE 3-33 

ADJUSTING THE REAR BRAKE 3-34 

CHECKING THE BRAKE FLUID LEVEL 3-35 

CHECKING THE BRAKE PADS 3-36 

ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-36 

CHECKING THE BRAKE HOSES 3-37 

BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-37 

ADJUSTING THE SHIFT PEDAL 3-38 

ADJUSTING THE DRIVE CHAIN SLACK 3-39 

LUBRICATING THE DRIVE CHAIN 3-41 

CHECKING AND ADJUSTING THE STEERING HEAD 3-41 

CHECKING THE FRONT FORK 3-43 

ADJUSTING THE FRONT FORK LEGS 3-43 

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-45 

CHECKING THE TIRES 3-47 



CHK 
ADJ 


<& 



CHECKING AND LUBRICATING THE CABLES 3-50 

LUBRICATING THE LEVERS AND PEDALS 3-50 

LUBRICATING THE SIDESTAND 3-50 

LUBRICATING THE REAR SUSPENSION 3-50 

ELECTRICAL SYSTEMS 3-51 

CHECKING AND CHARGING THE BATTERY 3-51 

CHECKING THE FUSES 3-56 

REPLACING THE HEADLIGHT BULBS 3-58 

ADJUSTING THE HEADLIGHT BEAMS 3-59 

ADJUSTING THE DIGITAL CLOCK 3-59 



CHK 
ADJ 


<a 



INTRODUCTION 
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 



PERIODIC CHECKS AND ADJUSTMENTS 

INTRODUCTION 

This chapter includes all information necessary to perforin recommended checks and adjustments. If 
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a 
longer service life and reduce the need for costly overhaul work. This information applies to vehicles 
already in service as well as to new vehicles that are being prepared for sale. All service technicians 
should be familiar with this entire chapter. 

EAS00037 

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 

NOTE: 

• The annual checks must be performed every year, except if a kilometer-based maintenance 
is performed instead. 

• From 50,000 km, repeat the maintenance intervals starting from 10,000 km. 

• Items marked with an asterisk should be performed by a Yamaha dealer as they require special 
tools, data and technical skills. 





NO. 


ITEM 


CHECK OR MAINTENANCE JOB 


ODOMETER READING (x 1,000 km) 


ANNUAL 
CHECK 


1 


10 


20 


30 


40 


1 


* 


Fuel line 

(See page 3-24) 


• Check fuel hoses for cracks or damage. 




V 


V 


V 


V 


V 


2 


* 


Fuel filter 
(See page 3-24) 


• Check condition. 






V 




V 




3 




Spark plugs 
(See page 3-15) 


• Check condition. 

• Clean and regap. 




V 




V 






• Replace. 






V 




V 




4 


* 


Valves 
(See page 3-5) 


• Check valve clearance. 

• Adjust. 


Every 40,000 km 


5 




Air filter element 
(See page 3-23) 


• Clean. 




V 




V 






• Replace. 






V 




V 




6 




Clutch 

(See page 3-22) 


• Check operation. 

• Adjust. 


V 


V 


V 


V 


V 




7 


* 


Front brake 
(See page 3-35) 
(See page 3-36) 


• Check operation, fluid level and vehicle 
for fluid leakage. (See NOTE) 


V 


V 


V 


V 


V 


V 


• Replace brake pads. 


Whenever worn to the limit 


8 


* 


Rear brake 
(See page 3-35) 
(See page 3-36) 


• Check operation, fluid level and vehicle 
for fluid leakage. (See NOTE) 


V 


V 


V 


V 


V 


V 


• Replace brake pads. 


Whenever worn to the limit 


9 


* 


Brake hoses 
(See page 3-37) 


• Check for cracks or damage. 




V 


V 


V 


V 


V 


• Replace. (See NOTE) 


Every 4 years 


10 


* 


Wheels 

(See page 4-4) 


• Check runout and for damage. 




V 


V 


V 


V 




11 


* 


Tires 

(See page 3-47) 


• Check tread depth and for damage. 

• Replace if necessary. 

• Check air pressure. 

• Correct if necessary. 




V 


V 


V 


V 




12 


* 


Wheel bearings 
(Seep age 4-4) 


• Check bearing for looseness or damage. 




V 


V 


V 


V 




13 


* 


Swingarm 
(See page 4-68) 
(See page 4-69) 


• Check operation and for excessive play. 




V 


V 


V 


V 




• Lubricate with lithium-soap-based grease. 


Every 50,000 km 


14 




Drive chain 
(See page 3-39) 
(See page 4-69) 


• Check chain slack. 

• Make sure that the rear wheel is properly 
aligned. 

• Clean and lubricate. 


Every 1 ,000 km and after washing the 
motorcycle or riding in the rain. 


15 


* 


Steering bearings 
(See page 3-41 ) 
(See page 4-59) 


• Check bearing play and steering for 
roughness. 


V 


V 


V 


V 


V 




• Lubricate with lithium-soap-based grease. 


Every 20,000 km 



3-1 



PERIODIC MAINTENANCE/LUBRICATION INTERVALS 



CHK 
ADJ 


<a 



NO. 


ITEM 


CHECK OR MAINTENANCE JOB 


ODOMETER READING (x 1,000 km) 


ANNUAL 
CHECK 


1 


10 


20 


30 


40 


16 


* 


Chassis fasteners 
(See page 2-22) 


• Make sure that all nuts, bolts and 
screws and properly tightened. 




V 


V 


V 


V 


V 


17 




Sidestand/ 
centerstand 
(Seep age 3-50) 


• Check operation. 

• Lubricate. 




V 


V 


V 


V 


V 


18 


* 


Sidestand switch 
(See page 8-21) 


• Check operaiton. 


V 


V 


V 


V 


V 


V 


19 


* 


Front fork 
(See page 3-43) 


• Check operation and for oil leakage. 




V 


V 


V 


V 




20 


* 


Rear shock 
absorber 
assembly 
(See page 4-64) 


• Check operation and shock absorber for 
oil leakage. 




V 


V 


V 


V 




21 


* 


Rear suspension 
relay arm and 
connecting arm 
pivoting points 
(See page 4-69) 


• Check operation. 




V 


V 


V 


V 




• Lubricate with lithium-soap-based grease. 






V 




V 




22 


* 


Carburetors 
(See page 3-10) 
(See page 3-12) 


• Check starter (choke) operation. 

• Adjust engine idling speed and 
synchronization. 


V 


V 


V 


V 


V 


V 


23 




Engine oil 
(See page 3-20) 


• Change. 


V 


V 


V 


V 


V 


V 


24 




Engine oil filter 
cartridge 
(See page 3-20) 


• Replace. 


V 




V 




V 




25 


* 


Cooling system 
(See page 3-29) 
(See page 3-30) 


• Check coolant level and vehicle, for 
coolant leakage 




V 


V 


V 


V 


V 


• Change. 


Every 3 years 


26 


* 


Front and rear 
brake switches 
(See page 3-36) 
(See page 8-38) 


• Chck operation. 


V 


V 


V 


V 


V 


V 


27 




Moving parts and 

cables 

(See page 2-24) 

(See page 3-50) 


• Lubricate. 




V 


V 


V 


V 


V 


28 


* 


Air induction 

system 

(See page 7-1 6) 


• Check the air cut valve and reed valve for 
damage. 

• Replace the entire air induction system if 
necessary. 




V 


V 


V 


V 


V 


29 


* 


Lights, signals 
and switches 
(See page 3-59) 
(See page 8-30) 
(See page 8-35) 


• Check operation. 

• Adjust headlight beam. 


V 


V 


V 


V 


V 


V 



*: It is recommended that these items be serviced by a Yamaha dealer. 
NOTE: 



• The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 

• Hydraulic brake service 

• Regularly check and, if necessary, correct the brake fluid level. 

• Every two years replace the internal components of the brake master cylinders and calipers, and 
change the brake fluid. 

• Replace the brake hoses every four years and if cracked or damaged. 



3-2 



FRONT COWLING 



CHK 
ADJ 


<a 



FRONT COWLING/SEAT/SIDE COVER/FUEL TANK 

FRONT COWLING 




Order 


Job/ Part 


Q'ty 


Remarks 


1 
2 
3 
4 


Removing the fron cowling 

Inner panel 

Headlight/meter coupler 
Front cowling assembly 
Back view mirror 


2 

1/1 
1 
2 


Remove the4 parts in the order listed. 
Disconnect. 


5 


Meter unit 


1 




6 


Headlight unit 


1 


For installation, reverse the removal 
procedure. 



3-3 



SEAT, SIDE COVER AND FUEL TANK 



EAS00040 

SEAT, SIDE COVER AND FUEL TANK 



CHK 
ADJ 


<a 



19Nm(1.9m«kg) 




4 Nm (0.4 rrvkg) 



Order 


Job/ Part 


Q'ty 


Remarks 




Removing the seat, side cover and 
fuel tank 




Remove the parts in the order listed. 


1 


Seat 


1 




2 
3 

4 


Side cover (left and right) 
Fuel sender coupler 
Fuel tank 


2 
1 

1 


Disconnect. 


5 


Fuel tank breather hose 


1 




6 


Fuel tank drain hose 


1 


NOTE: 


7 
8 


Fuel hose 
Grab bar 


1 
1 


Befor disconnecting the fuel hose, turn 
the fuel cock off. 




9 


Rear cowling 


1 


For installation, reverse the removal 
procedure. 



3-4 



ADJUSTING THE VALVE CLEARANCE 



CHK 
ADJ 


<a 



ENGINE 

ADJUSTING THE VALVE CLEARANCE 

The following procedure applies to all of the 
valves. 

NOTE: 

•Valve clearance adjustment should be made 
on a cold engine, at room temperature. 

• When the valve clearance is to be measured or 
adjusted, the piston must be at top dead center 
(TDC) on the compression stroke. 



1. Remove: 
•cylinder head cover 
Refer to "CYLINDER 
chapter 5. 



HEAD COVER" in 



2. Measure: 
•valve clearance 
Out of specification 



Adjust. 




Valve clearance (cold) 
Intake valve 

0.11 ~ 0.20 mm 
Exhaust valve 

0.21 ~ 0.25 mm 




a. Turn the crankshaft clockwise. 

b. When piston #1 is at TDC on the compres- 
sion stroke, align the TDC mark (a) on the 
pickup rotor with the crankcase mating sur- 
face®. 

NOTE: 

TDC on the compression stroke can be found 
when the camshaft lobes are turned away from 
each other. 

c. Measure the valve clearance with a thick- 
ness gauge®. 

NOTE: 

•If the valve clearance is incorrect, record the 

measured reading. 
•Measure the valve clearance in the following 

sequence. 



3-5 



Valve clearance measuring sequence 
Cylinder #1 -+ #2 -+ #4 -+ #3 



ADJUSTING THE VALVE CLEARANCE 







A 














/ 


> 




( 


^ 


^\r\r\ 


o 






\ 


v^ 


J V, 






Vj 










# 


1 # 


2 # 


3 


#4 




y 



[g 0° 180° 360° 540° 720° 
I > I 1 1 1 1 



E 


#1 


#2 


#3 


#4 



Ill 

SBE~ 



CHK 
ADJ 


<a 



El Front 

d. For each cylinder, starting with cylinder #1 at 
TDC, turn the crankshaft clockwise as speci- 
fied in the following table. 

\B\ Degrees that the crankshaft is turned clockwise 

LQ| Cylinder 

[0 Combustion cycle 



#2 Cylinder 


180° 


#4 Cylinder 


360° 


#3 Cylilnder 


540° 



3. Remove: 
•intake camshaft 
•exhaust camshaft 

NOTE: 



•Refer to "DISASSEMBLING THE ENGINE - 
CAMSHAFT AND CYLINDER HEAD" in chap- 
ter 5. 

•When removing the timing chain and cam- 
shafts, fasten a wire to the timing chain to re- 
trieve it if it falls into the crankcase. 





^^>^^ ) J 




^ 


T— 


11171102 



4. Adjust: 
•valve clearance 



a. Remove the valve lifter® and the valve pad 
(D with a valve lapper (3). 




Valve lapper 
90890-04101 



3-6 



ADJUSTING THE VALVE CLEARANCE 



CHK 
ADJ 


<a 





NOTE: 

•Cover the timing chain opening with a rag to 

prevent the valve pad from falling into the 

crankcase. 
• Make a note of the position of each valve lifter 

(D and valve pad (2) so that they can be 

installed in the correct place. 

b. Select the proper valve pad from the follow- 
ing table. 



Valve pad 
thickness range 


Available valve 
pads 


Nos. 
120 ~ 240 


1.20 ~ 
2.40 mm 


25 thicknesses 
in 0.05 mm 
increments 



NOTE: 

•The thickness® of each valve pad is marked 
in hundredths of millimeters on the side that 
touches the valve lifter. 

• Since valve pads of various sizes are originally 
installed, the valve pad number must be 
rounded in order to reach the closest equiva- 
lent to the original. 

c. Round off the original valve pad number ac- 
cording to the following table. 



Last digit 


Rounded value 


0or2 





5 


5 


8 


10 



EXAMPLE: 

Original valve pad number = 148 (thickness 

=1.48 mm (0.058 in)) 

Rounded value = 150 

d. Locate the rounded number of the original 
valve pad and the measured valve clearance 
in the valve pad selection table. The point 
where the column and row intersect is the 
new valve pad number. 

NOTE: 

The new valve pad number is only an approxi- 
mation. The valve clearance must be measured 
again and the above steps should be repeated if 
the measurement is still incorrect. 



3-7 



ADJUSTING THE VALVE CLEARANCE 



CHK 
ADJ 


<a 



VALVE PAD SELECTION TABLE 
INTAKE 





Measured 
clearance 

1 


INSTALLED PAD NUMBER 




120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




0.00 


~ 0.02 








120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 




0.03 


~ 0.07 






120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 




0.08 


~ 0.10 




120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 




0.11 


~ 0.20 


Specification 


exa 


0.21 


~ 0.22 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




-+ 


0.23 


~ 0.27 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.28 


~ 0.32 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.33 


~ 0.37 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.38 


~ 0.42 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.43 


~ 0.47 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.48 


~ 0.52 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.53 


~ 0.57 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.58 


~ 0.62 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.63 


~ 0.67 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.68 


~ 0.72 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.73 


~ 0.77 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.78 


~ 0.82 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.83 


~ 0.87 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.88 


~ 0.92 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.93 


~ 0.97 


200 


205 


210 


215 


220 


225 


230 


235 


240 




EXAMPLE: 




0.98 


~ 1.02 


205 


210 


215 


220 


225 


230 


235 


240 




VALVE CLEARANCE: 0.11 ~ 0.20 mm 




1.03 


~ 1.07 


210 


215 


220 


225 


230 


235 


240 




Installed is 150 




1.08 


~ 1.12 


215 


220 


225 


230 


235 


240 




Measured clearance is 0.25 mm 




1.13 


- 1.17 


220 


225 


230 


235 


240 




Replace 150 pad with 160 pad 




1.18 


~ 1.22 


225 


230 


235 


240 








1.23 


~ 1.27 


230 


235 


240 








1.28 


- 1.32 


235 


240 








1.33 


- 1.37 


240 



















































EXHAUST 





Measured 
clearance 

I 


INSTALLED PAD NUMBER 




120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




0.00 


~ 0.02 












120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 




0.03 


~ 0.07 










120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 




0.08 


~ 0.10 








120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 




0.13 


~ 0.17 






120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 




0.18 


~ 0.20 




120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 




0.21 


~ 0.30 


Specification 


exa 


0.31 


~ 0.32 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




-► 


0.33 


~ 0.37 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.38 


~ 0.42 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.43 


~ 0.47 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.48 


~ 0.52 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.53 


~ 0.57 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.58 


~ 0.62 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.63 


~ 0.67 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.68 


~ 0.72 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.73 


~ 0.77 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.78 


~ 0.82 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.83 


~ 0.87 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.88 


~ 0.92 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.93 


~ 0.97 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.98 


- 1.02 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








1.30 


~ 1.07 


200 


205 


210 


215 


220 


225 


230 


235 


240 




EXAMPLE: 




1.08 


- 1.12 


205 


210 


215 


220 


225 


230 


235 


240 




VALVE CLEARANCE: 0.21 ~ 0.30 mm 




1.13 


~ 1.17 


210 


215 


220 


225 


230 


235 


240 




Installed is 175 




1.18 


- 1.22 


215 


220 


225 


230 


235 


240 




Measured clearance is 0.35 mm 




1.23 


~ 1.27 


220 


225 


230 


235 


240 




Reolace 1 75 oad with 1 85 oad 




1.28 


- 1.32 


225 


230 


235 


240 








1.33 


~ 1.37 


230 


235 


240 








1.38 


- 1.42 


235 


240 








1.43 


~ 1.47 


240 



















































3-8 



ADJUSTING THE VALVE CLEARANCE 



CHK 
ADJ 


<& 




e. Install the new valve pad ® and the valve lift- 
er (2). 

NOTE: 

•Apply molybdenum disulfide to the valve pad. 

• Lubricate the valve lifter with molybdenum dis- 
ulfide oil. 

•The valve lifter must turn smoothly when ro- 
tated by hand. 

• Install the valve lifter and the valve pad in the 
correct place. 

f. Install the exhaust and intake camshafts, 
timing chain and camshaft caps. 



V 



Camshaft cap bolt 
10Nm(1.0iTTkg) 



NOTE: 

•Refer to "ASSEMBLING AND ADJUSTING 
THE ENGINE-CYLINDER HEAD AND CAM- 
SHAFT" in chapter 4. 

•Lubricate the camshaft bearings, camshaft 
lobes and camshaft journals. 

• First, install the exhaust camshaft. 

•Align the camshaft marks with the camshaft 
cap marks. 

• Rotate the crankshaft clockwise several turns 
to seat the parts. 

g. Measure the valve clearance again. 

h. If the valve clearance is still out of specifica- 
tion, repeat all of the valve clearance adjust- 
ment steps until the specified clearance is 
obtained. 



5. Install: 
•cylinder head cover 

Refer to "CYLINDER 
chapter 5. 

6. Install: 

•all removed parts 

NOTE: 



HEAD COVER" in 



For installation, reverse the removal procedure. 
Note the following points. 



3-9 



SYNCHRONIZING THE CARBURETORS 



CHK 
ADJ 


<a 



SYNCHRONIZING THE CARBURETORS 
NOTE: 

Prior to synchronizing the carburetors, the valve 
clearance and the engine idling speed should 
be properly adjusted and the ignition timing 
should be checked. 



1 . Stand the motorcycle on a level surface. 

NOTE: 

Place the motorcycle on a suitable stand. 




2. Remove: 
•vacuum cap 



3. Install: 
•vacuum gauge® 
• engine tachometer (2) 
(to the spark plug lead of cyl. #1) 



P 



Vacuum gauge 
90890-03094 

Engine tachometer 
90890-03113 



4. Start the engine and let it warm up for several 
minutes. 

5. Check: 

•engine idling speed 
Out of specification -► Adjust. 
Refer to "ADJUSTING THE ENGINE IDLING 
SPEED". 



€\ 



Engine idling speed 
1,050 ~ 1,150 r/min 



3-10 



SYNCHRONIZING THE CARBURETORS 



CHK 
ADJ 


<a 



<?> 


~f <p 








ffla-i 


LLfej 




Sl^^'iF 


T^ipnTW 


— /->gfj> y 


iSp^t 




~p_^LK^— ^B 


IBftr T 


Kffo_^h 




f^^^^ 








Pl-^" 



6. Adjust: 
•carburetor synchronization 



a. Synchronize carburetor #1 to carburetor #2 
by turning the synchronizing screw® in ei- 
ther direction until both gauges read the 
same. 



NOTE: 

After each step, rev the engine two or three 
times, each time for less than a second, and 
check the synchronization again. 

b. Synchronize carburetor #4 to carburetor #3 
by turning the synchronizing screw© in ei- 
ther direction until both gauges read the 
same. 

c. Synchronize carburetor #2 to carburetor #3 
by turning the synchronizing screw® in ei- 
ther direction until both gauges read the 
same. 




Vacuum pressure at engine idling 
speed 

30 kPa (225 mm Hg) 



NOTE: 

The difference in vacuum pressure between 
two carburetors should not exceed 1 .33 kPa (1 
mm Hg). 



Measure: 
■ engine idling speed 

Out of specification -► Adjust. 

Stop the engine and remove the measuring 

equipment. 

Adjust: 
■ throttle cable free play 

Refer to "ADJUSTING THE THROTTLE 

CABLE FREE PLAY". 




Throttle cable free play (at the 
flange of the throttle grip) 
3-5 mm 



10. Install: 
•vacuum cap 



3-11 



ADJUSTING THE ENGINE IDLING SPEED 



CHK 
ADJ 


<a 



ADJUSTING THE ENGINE IDLING SPEED 
NOTE: 

Prior to adjusting the engine idling speed, the 
carburetor synchronization should be adjusted 
properly, the air filter should be clean, and the 
engine should have adequate compression. 

1 . Start the engine and let it warm up for several 
minutes. 

2. Install: 

•engine tachometer 
(to the spark plug lead of cyl. #1) 



y- 



Engine tachometer 
90890-03113 



3. Measure: 
•engine idling speed 
Out of specification 



Adjust. 



€\ 



Engine idling speed 
1,050 ~ 1,150 r/min 




4. Adjust: 
•engine idling speed 



a. Turn the pilot screw® in or out until it is light- 
ly seated. 

b. Turn the pilot screw out the specified number 
of turns. 



v- 



Carburetor angle driver 2 
908900-03173 




Pilot screw 
2 turns out 



3-12 



ADJUSTING THE ENGINE IDLING SPEED/ 
ADJUSTING THE THROTTLE CABLE FREE PLAY 




CHK 
ADJ 


<a 



c. Turn the throttle stop screw© in direction (a) 
or® until the specified engine idling speed is 
obtained. 



Direction (a) 


Engine idling speed is in- 
creased. 


Direction © 


Engine idling speed is 
decreased. 



5. Adjust: 
•throttle cable free play 
Refer to "ADJUSTING 
CABLE FREE PLAY". 



THE THROTTLE 




Throttle cable free play (at the 
flange of the throttle grip) 
3 — 5 mm 



ADJUSTING THE THROTTLE CABLE FREE 
PLAY 

NOTE: 

Prior to adjusting the throttle cable free play, the 
engine idling speed and carburetor synchro- 
nization should be adjusted properly. 




1. Check: 
•throttle cable free play (a) 
Out of specification -► Adjust. 




Throttle cable free play (at the 
flange of the throttle grip) 
3-5 mm 



2. Remove: 
•seat 
•fuel tank 



3-13 



ADJUSTING THE THROTTLE CABLE FREE PLAY 



3. Adjust: 
•throttle cable free play 



CHK 
ADJ 


<a 




NOTE: 

When the motorcycle is accelerating, the accel- 
erator cable ® is pulled. 



Carburetor side 

a. Loosen the locknut (2) on the decelerator 
cable. 

b. Turn the adjusting nut (3) in direction (a) or® 
to take up any slack on the decelerator cable. 

c. Loosen the locknut (4) on the accelerator 
cable. 

d. Turn the adjusting nut (D in direction (a) or® 
until the specified throttle cable free play is 
obtained. 



Direction (a) 


Throttle cable free play is 
increased. 


Direction ® 


Throttle cable free play is 
decreased. 



e. Tighten the locknuts. 
NOTE: 



If the specified throttle cable free play cannot be 
obtained on the carburetor side of the cable, use 
the adjusting nut on the handlebar side. 




Handlebar side 

a. Loosen the locknut®. 

b. Turn the adjusting nut (2) in direction (a) or® 
until the specified throttle cable free play is 
obtained. 



Direction (a) 


Throttle cable free play is 
increased. 


Direction ® 


Throttle cable free play is 
decreased. 



c. Tighten the locknut. 



A WARNING 



After adjusting the throttle cable free play, 
turn the handlebar to the right and to the left 
to ensure that this does not cause the en- 
gine idling speed to change. 



3-14 



ADJUSTING THE THROTTLE CABLE FREE PLAY/ 

CHECKING THE SPARK PLUGS 

4. Install: 
•fuel tank 
•seat 



CHK 
ADJ 


<& 



CHECKING THE SPARK PLUGS 

The following procedure applies to all of the 
spark plugs. 

1. Disconnect: 
•sparkplug cap 

2. Remove: 
•spark plug 

CAUTION: 



Before removing the spark plugs, blow away 
any dirt accumulated in the spark plug wells 
with compressed air to prevent it from fal- 
ling into the cylinders. 




3. Check: 
•spark plug type 
Incorrect -► Change. 



Spark plug type (manufacturer) 
CR9E (NGK) 
U27ESR-N (DENSO) 



4. Check: 
•electrode® 

Damage/wear -► Replace the spark plug, 
•insulator© 

Abnormal color -► Replace the spark plug. 
Normal color is a medium-to-light tan color. 

5. Clean: 
•spark plug 

(with a spark plug cleaner or wire brush) 



6. Measure: 
•sparkplug gap® 
(with a wire gauge) 
Out of specification 



Regap. 




Spark plug gap 
0.7 ~ 0.8 mm 



3-15 



CHECKING THE SPARK PLUGS/ 
CHECKING THE IGNITION TIMING 



CHK 
ADJ 


<a 



7. Install: 
•spark plug 

NOTE: 



XI 13Nm(1.3m«kg) 



Before installing the spark plug, clean the spark 
plug and gasket surface. 



8. Connect: 
•sparkplug cap 



CHECKING THE IGNITION TIMING 

NOTE: 

Prior to checking the ignition timing, check the 
wiring connections of the entire ignition system. 
Make sure that all connections are tight and free 
of corrosion. 




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1. Remove: 
•timing plug® 



2. Install: 
•timing light® 
• engine tachometer (2) 
(to the spark plug lead of cyl. #1) 



y. 



Timing light 
90890-03141 

Engine tachometer 
90890-03113 



3. Check: 
•ignition timing 



a. Start the engine, warm it up for several min- 
utes, and then let it run at the specified en- 
gine idling speed. 



€\ 



Engine idling speed 
1,050 ~ 1,150 r/min 



3-16 



CHECKING THE IGNITION TIMING/ 
MEASURING THE COMPRESSION PRESSURE 



CHK 
ADJ 


<a 




b. Check that the mark® is within the required 
firing range © on the pickup coil rotor. 
Incorrect firing range — ► Check the ignition 
system. 

NOTE: 

The ignition timing is not adjustable. 



4. Remove: 
•timing light 
•engine tachometer 

5. Install: 
•timing plug 

EAS00065 

MEASURING THE COMPRESSION PRES- 
SURE 

The following procedure applies to all of the cyl- 
inders. 



NOTE: 

Insufficient compression pressure will result in a 
loss of performance. 

1. Measure: 
•valve clearance 

Out of specification -► Adjust. 
Refer to "ADJUSTING THE VALVE CLEAR- 
ANCE". 

2. Start the engine, warm it up for several min- 
utes, and then turn it off. 

3. Disconnect: 
•sparkplug cap 

4. Remove: 
•spark plug 

CAUTION: 



Before removing the spark plugs, use com- 
pressed air to blow away any dirt accumu- 
lated in the spark plug wells to prevent it 
from falling into the cylinders. 




5. Install: 
•compression gauge® 




Compression gauge 

90890-03081 
Compression gauge adapter 

90890-04136 



3-17 



MEASURING THE COMPRESSION PRESSURE 



CHK 
ADJ 


<a 



6. Measure: 

•compression pressure 
Above the maximum pressure — ► Inspect the 
cylinder head, valve surfaces, and piston 
crown for carbon deposits. 
Below the minimum pressure — ► Squirt a few 
drops of oil into the affected cylinder and 
measure again. 

Refer to the following table. 



Compression pressure 
(with oil applied into cylinder) 


Reading 


Diagnosis 


Higher than 
without oil 


Piston ring(-s) wear or 
damage -► Repair. 


Same as 
without oil 


Piston valves, cylinder 
head gasket or piston 
possibly defective -+ 
Repair. 

Compression pressure 
(at sea level) 



7R 


Compression pressure (at sea 


'A 


level): 


Standard: 


1,450 kPa (14.5 kg/cm 2 ) 


Minimum: 


1,260 kPa (12.6 kg/cm 2 ) 


Maximum: 


1,620 kPa (16.2 kg/cm 2 ) 



a. Turn the main switch to "ON". 

b. With the throttle wide open, crank the engine 
until the reading on the compression gauge 
stabilizes. 



A WARNING 



To prevent sparking, ground all spark plug 
leads before cranking the engine. 



NOTE: 

The difference in compression pressure be- 
tween cylinders should not exceed 100 kPa (1 
kg/cm 2 ). 



7. Install: 
•spark plug 

8. Connect: 
•sparkplug cap 



XI 13Nm(1.3m«kg) 



3-18 



CHECKING THE ENGINE OIL LEVEL 



CHK 
ADJ 


<a 



CHECKING THE ENGINE OIL LEVEL 

1 . Stand the motorcycle on a level surface. 

NOTE: 

• Place the motorcycle on a suitable stand. 
•Make sure that the motorcycle is upright. 

2. Let the engine idle for a few minutes. 




Check: 

►engine oil level 

The engine oil level should be between the 
minimum level marks® and maximum level 
marks®. 

Below the minimum level mark — ► Add the 
recommended engine oil to the proper level. 



Temp. 
-20-10 10 20 30 40 

i i 



10W/30 i 



-> 



I10W/40 



20W/40 



| 20W/50 



11750703 




>x$ 



Recommended engine oil 

Refer to the chart for the engine 
oil grade which is best suited 
for certain atmospheric temper- 
atures. 
API standard 

SE or higher grade 
ACEA standard 

G4 or G5 



CAUTION: 



• Engine oil also lubricates the clutch and 
the wrong oil types or additives could 
cause clutch slippage. Therefore, do not 
add any chemical additives or use engine 
oils with a grade of CD (a) or higher and do 
not use oils labeled "ENERGY CONSERV- 
ING II"® or higher. 

• Do not allow foreign materials to enter the 
crankcase. 

4. Start the engine, warm it up for several min- 
utes, and then turn it off. 

5. Check the engine oil level again. 

NOTE: 

Before checking the engine oil level, wait a few 
minutes until the oil has settled. 



3-19 



CHANGING THE ENGINE OIL 



CHK 
ADJ 


<a 



CHANGING THE ENGINE OIL 

1 . Start the engine, warm it up for several min- 
utes, and then turn it off. 

2. Place a container under the engine oil drain 
bolt. 




Remove: 

►engine oil filler cap® 
►engine oil drain bolt (2) 

(along with the gasket) 

Drain: 
►engine oil 

(completely from the crankcase) 

If the oil filter cartridge is also to be replaced, 

perform the following procedure. 



a. Remove the oil filter cartridge ® with an oil 
filter wrench (2). 




Oil filter wrench 
90890-01426 



b. Apply a thin coat of engine oil onto the O-ring 
® of the new oil filter cartridge. 

CAUTION: 



Make sure that the O-ring ® is positioned 
correctly in the groove of the oil filter car- 
tridge. 



3-20 



CHANGING THE ENGINE OIL 



CHK 
ADJ 


<& 




c. Tighten the new oil filter cartridge to specifi- 
cation with an oil filter wrench. 



V 



\ 



Oil filter cartridge 
17Nm(1.7irrkg) 



6. Check: 

•engine oil drain bolt gasket 
Damage -► Replace. 

7. Install: 

•engine oil drain bolt |XI 43 Nm (4.3 m«kg) 

8. Fill: 
•crankcase 

(with the specified amount of the recom 
mended engine oil) 



•ft 



Quantity 

Total amount 

3.7 L 

Without oil filter cartridge 
replacement 

2.8 L 

With oil filter cartridge replace- 
ment 
3.0 L 



9. Install: 

•engine oil filler cap 

1 0. Start the engine, warm it up for several min- 
utes, and then turn it off. 

11. Check: 
•engine 

(for engine oil leaks) 

12. Check: 
•engine oil level 

Refer to "CHECKING THE ENGINE OIL 
LEVEL". 

13. Check: 
•engine oil pressure 

a. Slightly loosen the oil gallery bolt®. 

b. Start the engine and keep it idling until en- 
gine oil starts to seep from the oil gallery bolt. 
If no engine oil comes out after one minute, 
turn the engine off so that it will not seize. 

c. Check the engine oil passages, the oil filter 
cartridge and the oil pump for damage or 
leakage. Refer to "OIL PAN AND OIL PUMP" 
in chapter 5. 

d. Start the engine after solving the problem(-s) 
and check the engine oil pressure again. 

e. Tighten the oil gallery bolt to specification. 



3-21 



CHANGING THE ENGINE OIL/ 
ADJUSTING THE CLUTCH CABLE FREE PLAY 



V 



CHK 
ADJ 


<a 



Oil gallery bolt 
10Nm(1.0m«kg) 











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ADJUSTING THE CLUTCH CABLE FREE 
PLAY 

1. Check: 
•clutch cable free play® 
Out of specification -+ Adjust. 




Clutch cable free play (at the end 
of the clutch lever) 
10 ~ 15 mm 



2. Adjust: 
•clutch cable free play 



Handlebar side 

a. Loosen the locknut®. 

b. Turn the adjusting bolt ® in direction @ or® 
until the specified clutch cable free play is ob- 
tained. 



Direction @ 


Clutch cable free play is 
increased. 


Direction ® 


Clutch cable free play is 
decreased 



c. Tighten the locknut. 
NOTE: 



If the specified clutch cable free play cannot be 
obtained on the handlebar side of the cable, use 
the adjusting nut on the engine side. 

Engine side 

a. Loosen the locknuts®. 

b. Turn the adjusting bolt® in direction @ or® 
until the specified clutch cable free play is ob- 
tained. 



Direction @ 


Clutch cable free play is 
increased. 


Direction ® 


Clutch cable free play is 
decreased 



c. Tighten the locknuts. 



3-22 



CLEANING THE AIR FILTER ELEMENT 



CHK 
ADJ 


<a 




CLEANING THE AIR FILTER ELEMENT 

1. Remove: 
•seat 
•fuel tank 
•side cover 
• cover ® 



2. Remove: 
• air filter case cover ® 
•air filter element 



3. Clean: 
•air filter element 

Apply compressed air to the outer surface of 
the air filter element. 



■IP 



I. Check: 
•air filter element 
Damage -► Replace. 

3. Install: 
•air filter element 
•air filter case cover 

CAUTION: 



Never operate the engine without the air fil- 
ter element installed. Unfiltered air will 
cause rapid wear of engine parts and may 
damage the engine. Operating the engine 
without the air filter element will also affect 
the carburetor tuning, leading to poor en- 
gine performance and possible overheat- 
ing. 



3-23 



CLEANING THE AIR FILTER ELEMENT/ 

CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS/ 

CHECKING THE FUEL HOSES AND FUEL FILTER 



CHK 
ADJ 


<a 




NOTE: 

When installing the air filter element into the air 
filter case cover, be sure their sealing surfaces 
are aligned to prevent any air leaks. 

6. Install: 
• cover 
•side cover 
•fuel tank 
•seat 

EAS00095 

CHECKING THE CARBURETOR JOINTS 
AND INTAKE MANIFOLDS 

The following procedure applies to all of the car- 
buretor joints and intake manifolds. 
1. Remove: 

•seat 

•fuel tank 

•air filter case panel® 



2. Check: 
•carburetor joint® 
•intake manifold (2) 

Cracks/damage -► Replace. 

Refer to "CARBURETOR" in chapter 6. 

3. Install: 

•air chamber cover 
•fuel tank 
•seat 



EAS00097 

CHECKING THE FUEL HOSES AND FUEL 
FILTER 

The following procedure applies to all of the fuel 

hoses. 

1. Remove: 

•seat 

•fuel tank 

•side cover 



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2. Check: 
•fuel hose© 

Cracks/damage ->- Replace, 
•fuel filter (2) 

Damage/dirt -k Replace. 



3-24 



CHECKING THE FUEL HOSES AND FUEL FILTER/ 

CHECKING THE CRANKCASE BREATHER HOSE/ 

CHECKING THE EXHAUST SYSTEM 



CHK 
ADJ 


<a 




NOTE: 

•Drain and flush the fuel tank if abrasive dam- 
age to any components of the fuel line is evi- 
dent. 

• The arrow mark® on the fuel filter should face 
to the side of the fuel pump ® . 

3. Install: 
•side cover 
•fuel tank 
•seat 




CHECKING THE CRANKCASE BREATHER 
HOSE 

1. Remove: 
•seat 
•fuel tank 

2. Check: 

•crankcase breather hose ® 
Cracks/damage -► Replace. 
Loose connection -► Connect properly. 

CAUTION: 



Make sure that the crankcase breather hose 
is routed correctly. 

3. Install: 
•fuel tank 
•seat 

EAS00099 

CHECKING THE EXHAUST SYSTEM 

The following procedure applies to all of the ex- 
haust pipes and gaskets. 

1. Check: 
•exhaust pipe® 
•muffler® 

Cracks/damage -► Replace. 
• gasket (3) 
Exhaust gas leaks -► Replace. 

2. Check: 
•tightening torque 



X 



Exhaust pipe nut (4) 

20 Nm (2.0 nrkg) 
Exhaust pipe and muffler bolt (5) 

20 Nm (2.0 nrkg) 
Exhaust pipe and bracket bolt ® 

20 Nm (2.0 nrkg) 
Muffler and muffler bracket bolt (7) 

48 Nm (4.8 nrkg) 



3-25 



ADJUSTING THE EXUP CABLES 



CHK 
ADJ 


<a 



EAS00101 

ADJUSTING THE EXUP CABLES 

1. Remove: 
•seat 
•fuel tank 




2. Remove: 
• EXUP valve pulley cover ® 



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j^v)V\^ — -^ 




t^ 




3. Check: 
•EXUP operation 



a. Disconnect the EXUP servomotor connector 



b. Connect the battery to the EXUP servomotor 
connector and check if the servomotor oper- 
ates properly. 



Battery positive lead - 
Battery negative lead 



black/yellow(2) 
► black/red® 



CAUTION: 



To avoid damaging the servomotor, do not 
leave the battery connected to it for more 
than a few seconds. 



c. Check that the EXUP valve operates properly. 

d. Connect the EXUP servomotor connector. 



3-26 



ADJUSTING THE EXUP CABLES/ 
CHECKING THE COOLANT LEVEL 



CHK 
ADJ 


<a 





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4. Check: 
•EXUP cable free play® 




EXUP cable free play 
1.5 mm max. 



5. Adjust: 
• EXUP cable free play 



a. Loosen both locknuts®. 

b. Insert a 4 mm long pin through the notch in 
the EXUP valve pulley and into the hole in the 
EXUP valve cover. 

c. Turn both adjusting bolts (2) counterclock- 
wise until there is no EXUP cable free play. 

d. Turn both adjusting bolts 1 12 of a turn clock- 
wise. 

e. Tighten both locknuts and then remove the 
pin. 

6. Install: 

• EXUP valve pulley cover 

XI 10Nm(1.0m«kgj~ 

7. Install: 
•fuel tank 
•seat 




CHECKING THE COOLANT LEVEL 

1 . Stand the motorcycle on a level surface. 

NOTE: 

• Place the motorcycle on a suitable stand. 
•Make sure that the motorcycle is upright. 

2. Check: 
•coolant level 

The coolant level should be between the 

maximum level mark® and minimum level 

marks®. 

Below the minimum level mark — ► Add the 

recommended coolant to the proper level. 



3-27 



CHECKING THE COOLANT LEVEL 



CHK 
ADJ 


<a 



CAUTION: 



• Adding water instead of coolant lowers the 
antifreeze content of the coolant. If water is 
used instead of coolant, check and correct 
the antifreeze concentration of the coolant. 

• Use only distilled water. Soft water may be 
used if distilled water is not available. 

3. Start the engine, warm it up for several min- 
utes, and then turn it off. 

4. Check: 
•coolant level 

NOTE: 

Before checking the coolant level, wait a few 
minutes until it settles. 



3-28 



CHECKING THE COOLING SYSTEM 



CHK 
ADJ 


<a 



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CHECKING THE COOLING SYSTEM 

1. Check: 
•radiator® 
•radiator inlet hose (2) 

• radiator outlet hose (3) 

• oil cooler inlet hose (4) 

• oil cooler outlet hose (5) 
•water jacket inlet joint (6) 
•water pump outlet joint (7) 

Cracks/damage -► Replace. 

Refer to "COOLING SYSTEM" in chapter 5. 




3-29 



CHANGING THE COOLANT 



CHK 
ADJ 


<a 




CHANGING THE COOLANT 

1. Remove 
•seat 
•fuel tank 
•front cowling 
•rear suspension 

Refer to "REAR SHOCK ABSORBER AS- 
SEMBLY" in chapter 4. 

2. Disconnect: 

•coolant reservoir hose ® 

3. Drain: 
•coolant 

(from the coolant reservoir) 




Remove: 
•radiator cap® 



A WARNING 



A hot radiator is under pressure. Therefore, 
do not remove the radiator cap when the en- 
gine is hot. Scalding hot fluid and steam may 
be blown out, which could cause serious in- 
jury. When the engine has cooled, open the 
radiator cap as follows: 
Place a thick rag or a towel over the radiator 
cap and slowly turn the radiator cap coun- 
terclockwise toward the detent to allow any 
residual pressure to escape. When the his- 
sing sound has stopped, press down on the 
radiator cap, while still pressing down turn it 
counterclockwise, and then remove it. 

The following procedure applies to all of the 
coolant drain bolts and copper washers. 




Remove: 
►coolant drain bolt® 

(along with the copper washer) 

Drain: 
►coolant 

(from the engine and radiator) 



3-30 



CHANGING THE COOLANT 



CHK 
ADJ 


<a 




7. Check: 
•copper washer® 
•coolant drain bolt (2) 

Damage -► Replace. 

8. Install: 
•coolant drain bolt 



XI 7Nm(0.7m«kg) 



9. Connect: 
•coolant reservoir hose 

10. Fill: 
•cooling system 

(with the specified amount of the recom- 
mended coolant) 



Recommended antifreeze 

High-quality ethylene glycol anti 
freeze containing corrosion inhibi 
tors for aluminum engines 

Mix ratio 

50% antifreeze/50% water 



*Q 



Quantity 

Total amount 

2.4 L 
Coolant reservoir capacity 

0.3 L 
From minimum to maximum 
level mark 

0.2 L 



Handling notes for coolant 

Coolant is potentially harmful and should be 
handled with special care. 



A WARNING 



• If coolant splashes in your eyes, thorough- 
ly wash them with water and consult a doc- 
tor. 

• If coolant splashes on your clothes, quick- 
ly wash it away with water and then with 
soap and water. 

•If coolant is swallowed, induce vomiting 
and get immediate medical attention. 



3-31 



CHANGING THE COOLANT 



CHK 
ADJ 


<a 



CAUTION: 



• Adding water instead of coolant lowers the 
antifreeze content of the coolant. If water is 
used instead of coolant, check, and if nec- 
essary, correct the antifreeze concentra- 
tion of the coolant. 

• Use only distilled water. Soft water may be 
used if distilled water is not available. 

•If coolant comes into contact with painted 
surfaces, immediately wash them with wa- 
ter. 

• Do not mix different types of antifreeze. 

11. Install: 
•radiator cap 




12. Fill: 
•coolant reservoir 

(with the recommended coolant to the maxi- 
mum level mark®) 

13. Install: 

•coolant reservoir cap 

1 4. Start the engine, warm it up for several min- 
utes, and then turn it off. 

15. Check: 
•coolant level 

Refer to "CHECKING THE COOLANT LEV- 
EL". 

NOTE: 

Before checking the coolant level, wait a few 
minutes until it settles. 

16. Install: 

•rear suspension 
Refer to "REAR SHOCK ABSORBER AS- 
SEMBLY" in chapter 4. 

•fuel tank 

•seat 



3-32 



ADJUSTING THE FRONT BRAKE 



CHK 
ADJ 


<a 




CHASSIS 

ADJUSTING THE FRONT BRAKE 

1. Adjust: 
• brake lever position 
(distance® from the throttle grip to the brake 
lever) 

a. While pushing the brake lever forward, turn 
the adjusting dial ® until the brake lever is in 
the desired position. 

NOTE: 

Be sure to align the setting on the adjusting dial 
with the arrow mark (2) on the brake lever hold- 
er. 



Position #1 


Distance® is the larg- 
est. 


Position #4 


Distance® is the small- 
est. 



A WARNING 



•After adjusting the brake lever position, 
make sure that the pin on the brake lever 
holder is firmly inserted in the hole in the 
adjusting dial. 

•A soft or spongy feeling in the brake lever 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system . Air in the brake system will con- 
siderably reduce braking performance and 
could result in loss of control and possibly 
an accident. Therefore, check and, if nec- 
essary, bleed the brake system. 

CAUTION: 



After adjusting the brake lever position, 
make sure that there is no brake drag. 



3-33 



ADJUSTING THE REAR BRAKE 




CHK 
ADJ 


<& 



ADJUSTING THE REAR BRAKE 

1. Check: 
• brake pedal position 
(distance ® from the top of the rider footrest 
to the top of the brake pedal) 
Out of specification -► Adjust. 




Brake pedal position (below the 
top of the rider footrest) 
40 mm 



2. Adjust: 
• brake pedal position 



a. Loosen the locknut (T). 

b. Turn the adjusting bolt (2) in direction @ or® 
until the specified brake pedal position is ob- 
tained. 



Direction (a) 


Brake pedal is raised. 


Direction © 


Brake pedal is lowered. 



A WARNING 



After adjusting the brake pedal position, 
check that the end of the adjusting bolt (2) is 
visible through the hole ©. 

c. Tighten the locknut® to specification. 



V 



Locknut 

18Nm(1.8nvkg) 



A WARNING 



A soft or spongy feeling in the brake pedal 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system . Air in the brake system will consid- 
erably reduce braking performance and 
could result in loss of control and possibly 
an accident. Therefore, check and, if neces- 
sary, bleed the brake system. 

CAUTION: 



After adjusting the brake pedal position, 
make sure that there is no brake drag. 



3-34 



ADJUSTING THE REAR BRAKE/ 
CHECKING THE BRAKE FLUID LEVEL 



CHK 
ADJ 


<a 




3. Adjust: 
• rear brake light switch 
Refer to "ADJUSTING THE REAR BRAKE 
LIGHT SWITCH". 

EAS00115 

CHECKING THE BRAKE FLUID LEVEL 

1 . Stand the motorcycle on a level surface. 

NOTE: 

• Place the motorcycle on a suitable stand. 
•Make sure that the motorcycle is upright. 

2. Check: 
•brake fluid level 

Below the minimum level mark® — ► Add the 
recommended brake fluid to the proper level. 



•Y> 



Recommended brake fluid 
DOT 4 



BJ 


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U -— r^^ 


c: 


Wo 


) Hm) 





[A] Front brake 
\B\ Rear brake 



A WARNING 



• Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance. 

• Refill with the same type of brake fluid that 
is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor- 
mance. 

• When refilling, be careful that water does 
not enter the reservoir. Water will signifi- 
cantly lower the boiling point of the brake 
fluid and could cause vapor lock. 



CAUTION: 



Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 



NOTE: 

In order to ensure a correct reading of the brake 
fluid level, make sure that the top of the reser- 
voir is horizontal. 



3-35 



CHECKING THE BRAKE PADS/ 
ADJUSTING THE REAR BRAKE LIGHT SWITCH 



CHK 
ADJ 


<a 



BT 



K 



^ 



ZT 



2 




CHECKING THE BRAKE PADS 

The following procedure applies to all of the 
brake pads. 

1 . Operate the brake. 

2. Check: 
•front brake pad 
• rear brake pad 

Wear indicator groove ® almost disap- 
peared -+ Replace the brake pads as a set. 
Refer to "REPLACING THE FRONT BRAKE 
PADS" and "REPLACING THE REAR 
BRAKE PADS" in chapter 4. 

[A] Front brake 

\B\ Rear brake 

EAS00128 

ADJUSTING THE REAR BRAKE LIGHT 
SWITCH 

NOTE: 

The rear brake light switch is operated by move- 
ment of the brake pedal. 
The rear brake light switch is properly adjusted 
when the brake light comes on just before the 
braking effect starts. 

1. Check: 
•rear brake light operation timing 
Incorrect -► Adjust. 



F=t^ 




2. Adjust: 
•rear brake light operation timing 

a. Hold the main body ® of the rear brake light 
switch so that it does not rotate and turn the 
adjusting nut (2) indirection® or® until the 
rear brake light comes on at the proper time. 



Direction @ 


Brake light comes on 
sooner. 


Direction ® 


Brake light comes on lat- 
er. 



3-36 



CHECKING THE BRAKE HOSES/ 
BLEEDING THE HYDRAULIC BRAKE SYSTEM 



CHK 
ADJ 


<a 




CHECKING THE BRAKE HOSES 

The following procedure applies to all of the 
brake hoses and clamps. 

1. Check: 

• brake hose ® 
Cracks/damage/wear -► Replace. 

2. Check: 

• brake hose clamp (2) 
Loose connection — ► Tighten. 

3. Hold the motorcycle upright and apply the 
brake. 

4. Check: 

• brake hose ® 

Activate the brake several times. 

Brake fluid leakage -► Replace the damaged 

hose. 

Refer to "FRONT AND REAR BRAKES" in 

chapter 4. 



BLEEDING THE HYDRAULIC BRAKE SYS- 
TEM 



A WARNING 




Bleed the hydraulic brake system whenev- 
er: 

•the system was disassembled, 
•a brake hose was loosened or removed, 
•the brake fluid level is very low, 
•brake operation is faulty. 

1. Remove: 
•reservoir cap® 
•diaphragm (2) 

NOTE: 

•Be careful not to spill any brake fluid or allow 
the brake master cylinder reservoir or brake 
fluid reservoir to overflow. 

•When bleeding the hydraulic brake system, 
make sure that there is always enough brake 
fluid before applying the brake. Ignoring this 
precaution could allow air to enter the hydrau- 
lic brake system, considerably lengthening the 
bleeding procedure. 

• If bleeding is difficult, it may be necessary to let 
the brake fluid settle for a few hours. Repeat 
the bleeding procedure when the tiny bubbles 
in the hose have disappeared. 



3-37 



BLEEDING THE HYDRAULIC BRAKE SYSTEM/ 
ADJUSTING THE SHIFT PEDAL 



2. Bleed: 
• hydraulic brake system 



CHK 
ADJ 


<a 




a. Add the recommended brake fluid to the 
proper level. 

b. Install the diaphragm (brake master cylinder 
reservoir or brake fluid reservoir). 

c. Connect a clear plastic hose ® tightly to the 
bleed screw (2). 

El Front 
\E Rear 

d. Place the other end of the hose into a con- 
tainer. 

e. Slowly apply the brake several times. 

f. Fully squeeze the brake lever or fully de- 
press the brake pedal and hold it in position. 

g. Loosen the bleed screw. 

This will release the tension and cause the 

brake lever to contact the throttle grip or the 

brake pedal to fully extend, 
h. Tighten the bleed screw and then release the 

brake lever or brake pedal, 
i. Repeat steps (e) to (h) until all of the air 

bubbles have disappeared from the brake 

fluid in the plastic hose. 

Tighten the bleed screw to specification. 



J- 



V 



% 



Bleed screw 

6 Nm (0.6 irrkg) 



k. Fill the reservoir to the proper level. 

Refer to "CHECKING THE BRAKE FLUID 
LEVEL". 



A WARNING 



After bleeding the hydraulic brake system, 
check the brake operation. 




ADJUSTING THE SHIFT PEDAL 

1. Check: 
•shift pedal position 
(distance (a) from the top of the rider footrest 
to the top of the shift pedal) 
Out of specification -► Adjust. 




Shift pedal position (below the 
top of the rider footrest) 
40 mm 



3-38 



ADJUSTING THE SHIFT PEDAL/ 
ADJUSTING THE DRIVE CHAIN SLACK 




CHK 
ADJ 


<a 



2. Adjust: 
•adjusting bolt length 



a. Loosen both locknuts®. 

b. Turn the adjusting bolt (2) in direction (a) or® 
to obtain the correct shift pedal position. 



Direction ® 


Shift pedal is raised. 


Direction © 


Shift pedal is lowered. 



►Tighten both locknuts. 



ADJUSTING THE DRIVE CHAIN SLACK 
NOTE: 

The drive chain slack must be checked at the 
tightest point on the chain. 



CAUTION: 



A drive chain that is too tight will overload 
the engine and other vital parts, and one that 
is too loose can skip and damage the swin- 
garm or cause an accident. Therefore, keep 
the drive chain slack within the specified 
limits. 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 



NOTE: 

Place the motorcycle on a suitable stand so that 
the rear wheel is elevated. 




2. Rotate the rear wheel several times and 
check the drive chain to locate its tightest 
point. 



3. Check: 
•drive chain slack® 
Out of specification -+ Adjust. 




Drive chain slack 
40 ~ 50 mm 



3-39 



ADJUSTING THE DRIVE CHAIN SLACK 



CHK 
ADJ 


<a 




4. Adjust: 
•drive chain slack 



a. Loosen the brake caliper bracket bolt. 

b. Loosen the wheel axle nut®. 

c. Loosen both locknuts (2). 

d. Turn both adjusting nuts® in direction® or 
© until the specified drive chain slack is ob- 
tained. 



Direction (a) 


Drive chain is tightened. 


Direction © 


Drive chain is loosened. 



NOTE: 

To maintain the proper wheel alignment, adjust 
both sides evenly. 

e. Tighten both locknuts to specification. 



X 



Locknut 

16Nm(1.6irrkg) 



f. Tighten the wheel axle nut to specification. 



V 



\ 



Wheel axle nut 
150Nm(15nvkg) 



3-40 



LUBRICATING THE DRIVE CHAIN/ 
CHECKING AND ADJUSTING THE STEERING HEAD 



CHK 
ADJ 


<a 



LUBRICATING THE DRIVE CHAIN 

The drive chain consists of many interacting 
parts. If the drive chain is not maintained proper- 
ly, it will wear out rapidly. Therefore, the drive 
chain should be serviced, especially when the 
motorcycle is used in dusty areas. 
This motorcycle has a drive chain with small 
rubber O-rings between each side plate. Steam 
cleaning, high-pressure washing, certain sol- 
vents, and the use of a coarse brush can dam- 
age these O-rings. Therefore, use only kerosine 
to clean the drive chain. Wipe the drive chain dry 
and thoroughly lubricate it with engine oil or 
chain lubricant that is suitable for O-ring chains. 
Do not use any other lubricants on the drive 
chain since they may contain solvents that 
could damage the O-rings. 



•ft 



Recommended lubricant 

Engine oil or chain lubricant 
suitable forO-ring chains 



EAS00146 

CHECKING AND ADJUSTING THE STEER- 
ING HEAD 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 




NOTE: 

Place the motorcycle on a suitable stand so that 
the front wheel is elevated. 



2. Check: 
•steering head 

Grasp the bottom of the front fork legs and 

gently rock the front fork. 

Looseness or binding -► Adjust the steering 

head. 

3. Remove: 

•front cowling assembly 

Refer to "FRONT COWLING", 
•upper bracket 

Refer to "HANDLEBAR" and "STEERING 

HEAD" in chapter 4. 

4. Adjust: 
•steering head 

a. Remove the lock washer®, the upper ring 
nut (D, and the rubber washer (3). 



3-41 



CHECKING AND ADJUSTING THE STEERING HEAD 



CHK 
ADJ 


<& 





b. Loosen the lower ring nut® and then tighten 
it to specification with a ring nut wrench (5). 

NOTE: 

Set the torque wrench at a right angle to the ring 
nut wrench. 



y- 



Ring nut wrench 
90890-01403 



V 



Lower ring nut (initial tightening 
torque) 

52 Nm (5,2 irrkg) 



c. Loosen the lower ring nut® completely, then 
tighten it to specification. 



A WARNING 



Do not overtighten the lower ring nut. 



V 



Lower ring nut (final tightening 
torque) 

18Nm(1.8nrkg) 



d. Check the steering head for looseness or 
binding by turning the front fork all the way in 
both directions. If any binding is felt, remove 
the lower bracket and inspect the upper and 
lower bearings. 

Refer to "STEERING HEAD AND HAN- 
DLEBAR" in chapter 4. 



e. Install the rubber washer (7). 

f. Install the upper ring nut (8). 

g. Finger tighten the upper ring nut (8), then 
align the slots of both ring nuts. If necessary, 
hold the lower ring nut and tighten the upper 
ring nut until their slots are aligned. 

h. Install the lock washer (9). 



NOTE: 

Make sure that the lock washer tabs ® sit cor- 
rectly in the ring nut slots (b). 



5. Install: 
•upper bracket 
•front cowling assembly 



3-42 



CHECKING AND ADJUSTING THE STEERING HEAD/ 
CHECKING THE FRONT FORK/ADJUSTING THE FRONT FORK LEGS 



V 



CHK 
ADJ 


<& 



Steering stem nut 
110Nm(11 nvkg) 

Upper bracket pinch bolt 
30 Nm (3.0 nvkg) 

Handlebar holder bolt 
23 Nm (2.3 nvkg) 



CHECKING THE FRONT FORK 

1 . Stand the motorcycle on a level surface. 



A WARNING 




Securely support the motorcycle so that 
there is no danger of it falling over. 

2. Check: 
•inner tube 

Damage/scratches -► Replace, 
•oil seal 
Oil leakage -► Replace. 

3. Hold the motorcycle upright and apply the 
front brake. 

4. Check: 
•operation 

Push down hard on the handlebar several 

times and check if the front fork rebounds 

smoothly. 

Unsmooth operation -+ Repair. 

Refer to "FRONT FORK" in chapter 4. 

EAS00155 

ADJUSTING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 



A WARNING 



• Always adjust both front fork legs evenly. 
Uneven adjustment can result in poor han- 
dling and loss of stability. 

•Securely support the motorcycle so that 
there is no danger of it falling over. 

Spring preload 
CAUTION: 



•Grooves are provided to indicate the ad- 
justment position. 

• Never go beyond the maximum or mini- 
mum adjustment positions. 



3-43 



ADJUSTING THE FRONT FORK LEGS 






p-n 

rr 7i , 










41 Q 








"* 4 


(T T 1 








CHK 
ADJ 


<& 



1. Adjust: 
•spring preload 



a. Turn the adjusting bolt ® in direction (a) or 



Direction (a) 


Spring preload is 
increased (suspension is 
harder). 


Direction (g) 


Spring preload is 
decreased (suspension is 
softer). 



Adjusting positions 
Standard: 2 
Minimum: 5* 
Maximum: 1 



*fully turned out position 



Rebound damping 
CAUTION: 



Never go beyond the maximum or minimum 
adjustment positions. 

1. Adjust: 
•rebound damping 

a. Turn the adjusting screw® in direction (a) or 



Direction @ 


Rebound damping is 
increased (suspension is 
harder). 


Direction (5) 


Rebound damping is 
decreased (suspension is 
softer). 



Adjusting positions 
Standard: 7 clicks out* 
Minimum: 17 clicks out* 
Maximum: 1 clicks out* 



*: from the fully turned-in position 



3-44 



ADJUSTING THE FRONT FORK LEGS/ 
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 

Compression damping 
CAUTION: 




CHK 
ADJ 


<a 



Never go beyond the maximum or minimum 
adjustment positions. 



1. Adjust: 
•compression damping 



a. Turn the adjusting screw (T) in direction @ or 



Direction 


Compression damping is 
increased (suspension is 
harder). 


Direction 


Compression damping is 
decreased (suspension is 
softer). 



Adjusting positions 
Standard: 6 clicks out* 
Minimum: 21 clicks out* 
Maximum: 1 clicks out* 



*: from the fully turned-in position 



ADJUSTING THE REAR SHOCK ABSORB- 
ER ASSEMBLY 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

Spring preload 
CAUTION: 



Never go beyond the maximum or minimum 
adjustment positions. 

1. Adjust: 
•spring preload 

NOTE: 

Adjust the spring preload with the special 
wrench and extension bar included in the own- 
er's tool kit. 



3-45 



ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 



CHK 
ADJ 


<& 




a. Turn the adjusting ring ® in direction (a) or 

®. 

b. Align the desired position on the adjusting 
ring with the stopper (2). 



Direction (§) 


Spring preload is 
increased (suspension is 
harder). 


Direction © 


Spring preload is de- 
creased (suspension is 
softer). 



Adjusting positions 
Standard: 6 
Minimum: 1 
Maximum: 11 



Rebound damping 
CAUTION: 




Never go beyond the maximum or minimum 
adjustment positions. 

1. Adjust: 
•rebound damping 

a. Turn the adjusting knob® in direction (a) or 



Direction @ 


Rebound damping is 
increased (suspension is 
harder). 


Direction © 


Rebound damping is 
decreased (suspension is 
softer). 



Adjusting positions 
Standard: 20 clicks out* 
Minimum: 10 clicks out* 
Maximum: 3 clicks out* 



from the fully turned-in position 



3-46 



ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/ 

CHECKING THE TIRES 

Compression damping 
CAUTION: 




CHK 
ADJ 


<a 



Never go beyond the maximum or minimum 
adjustment positions. 



1. Adjust: 
•compression damping 



a. Turn the adjusting screw (T) in direction @ or 



Direction (a) 


Compression damping is 
increased (suspension is 
harder). 


Direction (§) 


Compression damping is 
decreased (suspension is 
softer). 



Adjusting positions 
Standard: 7 clicks in 
Minimum: 1 clicks in 
Maximum: 12 clicks in 



*: from the fully turned-out position 




EAS00162 

CHECKING THE TIRES 

The following procedure applies to both of the 
tires. 

1. Measure: 
•tire pressure 
Out of specification -+ Regulate. 



A WARNING 



• The tire pressure should only be checked 
and regulated when the tire temperature 
equals the ambient air temperature. 

• The tire pressure and the suspension must 
be adjusted according to the total weight 
(including cargo, rider, passenger and ac- 
cessories) and the anticipated riding 
speed. 

•Operation of an overloaded motorcycle 
could cause tire damage, an accident or an 
injury. 

NEVER OVERLOAD THE MOTORCYCLE. 



3-47 



CHECKING THE TIRES 



CHK 
ADJ 


<& 





12011003 



Basic weight 
(with oil and a 
full fuel tank) 


231 kg 


Maximum 
load* 


189 kg 


Cold tire 
pressure 


Front tire 


Rear tire 


Up to 90 kg 
load* 


250 kPa 
(2.5 kgf/cm 2 ) 


270 kPa 
(2.7 kgf/cm 2 ) 


90 kg ~ 
maximum load* 


250 kPa 
(2.5 kgf/cm 2 ) 


290 kPa 
(2.9 kgf/cm 2 ) 


High 
speed riding 


250 kPa 
(2.5 kgf/cm 2 ) 


290 kPa 
(2.9 kgf/cm 2 ) 



k : total of cargo, rider, passenger and accesso- 
ries 



A WARNING 



It is dangerous to ride with a worn-out tire. 
When the tire tread reaches the wear limit, 
replace the tire immediately. 

2. Check: 
•tire surfaces 
Damage/wear -► Replace the tire. 




Minimum tire tread depth 
1.6 mm 



® Tire tread depth 

(D Side wall 

(3) Wear indicator 



A WARNING 



•Do not use a tubeless tire on a wheel de- 
signed only for tube tires to avoid tire fail- 
ure and personal injury from sudden defla- 
tion. 

• When using a tube tire, be sure to install the 
correct tube. 

• Always replace a new tube tire and a new 
tube as a set. 

•To avoid pinching the tube, make sure that 
the wheel rim band and tube are centered in 
the wheel groove. 

• Patching a punctured tube is not recom- 
mended. If it is absolutely necessary to do 
so, use great care and replace the tube as 
soon as possible with a good quality re- 
placement. 



[A] Tire 



\E Wheel 



3-48 



CHECKING THE TIRES 



CHK 
ADJ 


<a 



Tube wheel 


Tube tire only 


Tubeless wheel 


Tube or tubeless tire 



•After extensive tests, the tires listed below 
have been approved by Yamaha Motor Co., 
Ltd. for this model. The front and rear tires 
should always be by the same manufactur- 
er and of the same design. No guarantee 
concerning handling characteristics can 
be given if a tire combination other than 
one approved by Yamaha is used on this 
motorcycle. 

Front tire 



Manufacturer 


Type 


Size 


BRIDGESTONE 


Tubeless 


120/70 
ZR17(58W) 


METZELER 


Tubeless 


120/70 
ZR17(58W) 



Rear tire 



Manufacturer 


Type 


Size 


BRIDGESTONE 


Tubeless 


180/55 
ZR17(73W) 


METZELER 


Tubeless 


180/55 
ZR17(73W) 



A WARNING 



New tires have a relatively low grip on the 
road surface until they have been slightly 
worn. Therefore, approximately 100 km 
should be traveled at normal speed before 
any highspeed riding is done. 




NOTE: 

For tires with a direction of rotation mark®: 
•Install the tire with the mark pointing in the 

direction of wheel rotation. 
•Align the mark (2) with the valve installation 

point. 



3-49 



CHECKING AND LUBRICATING THE CABLES/ 

LUBRICATING THE LEVERS AND PEDALS/ 

LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION 



CHK 
ADJ 


<a 



CHECKING AND LUBRICATING THE 
CABLES 

The following procedure applies to all of the 
cable sheaths and cables. 



A WARNING 



Damaged cable sheaths may cause the 
cable to corrode and interfere with its move- 
ment. Replace damaged cable sheaths and 
cables as soon as possible. 



1. Check: 
•cable sheath 

Damage -► Replace. 

2. Check: 
•cable operation 

Unsmooth operation - 



Lubricate. 



Recommended lubricant 

Engine oil or a suitable cable 
lubricant 



NOTE: 

Hold the cable end upright and pour a few drops 
of lubricant into the cable sheath or use a suit- 
able lubing device. 



LUBRICATING THE LEVERS AND PEDALS 

Lubricate the pivoting point and metal-to-metal 
moving parts of the levers and pedals. 



Recommended lubricant 
lithium soap base grease 



LUBRICATING THE SIDESTAND 

Lubricate the pivoting point and metal-to-metal 
moving parts of the sidestand. 



Recommended lubricant 
lithium soap base grease 



LUBRICATING THE REAR SUSPENSION 

Lubricate the pivoting point and metal-to-metal 
moving parts of the rear suspension. 



Recommended lubricant 
lithium soap base grease 



3-50 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


<a 





ELECTRICAL SYSTEM 

CHECKING AND CHARGING THE BATTERY 



A WARNING 



Batteries generate explosive hydrogen gas 
and contain electrolyte which is made of poi- 
sonous and highly caustic sulfuric acid. 
Therefore, always follow these preventive 
measures: 

• Wear protective eye gear when handling or 
working near batteries. 

•Charge batteries in a well-ventilated area. 

•Keep batteries away from fire, sparks or 
open flames (e.g., welding equipment, 
lighted cigarettes). 

•DO NOT SMOKE when charging or han- 
dling batteries. 

•KEEP BATTERIES AND ELECTROLYTE 
OUT OF REACH OF CHILDREN. 

• Avoid bodily contact with electrolyte as it 
can cause severe burns or permanent eye 
injury. 

First aid in case of bodily contact: 

External 

•SKIN - Wash with water. 

• EYES - Flush with water for 1 5 minutes and 
get immediate medical attention. 

Internal 

• Drink large quantities of water or milk fol- 
lowed with milk of magnesia, beaten egg or 
vegetable oil. Get immediate medical atten- 
tion. 

CAUTION: 



• This is a sealed battery. Never remove the 
sealing caps because the balance between 
cells will not be maintained and battery per- 
formance will deteriorate. 

•Charging time, charging amperage and 
charging voltage for a MF battery are differ- 
ent from those of conventional batteries. 
The MF battery should be charged as ex- 
plained in the charging method illustra- 
tions. If the battery is overcharged, the 
electrolyte level will drop considerably. 
Therefore, take special care when charging 
the battery. 



3-51 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


<a 










18350601 


Volt meier 


1 12.50V 1 




kI 





13.0 



Relationship between the open-circuit voltage 
and the charging time at 20°C 




5 6.5 10 

Charging time (hours) 

These values vary with the temperature, the condition of 
the battery plates, and the electrolyte level. 



NOTE: 

Since MF batteries are sealed, it is not possible 
to check the charge state of the battery by mea- 
suring the specific gravity of the electrolyte. 
Therefore, the charge of the battery has to be 
checked by measuring the voltage at the battery 
terminals. 

1. Remove: 
•seat 

2. Disconnect: 

• battery leads 
(from the battery terminals) 

CAUTION: 



First, disconnect the negative lead ®, then 
the positive lead (2). 

3. Remove: 

• battery 

4. Check: 

• battery charge 

a. Connect a pocket tester to the battery termi- 
nals. 



Tester positive lead - 


* battery positive 




terminal 


Tester negative lead - 


-+ battery negative 




terminal 



NOTE: 

•The charge state of a MF battery can be 
checked by measuring its open-circuit voltage 
(i.e., the voltage when the positive terminal is 
disconnected). 

•No charging is necessary when the open-cir- 
cuit voltage equals or exceeds 12.8 V. 



b. Check the charge of the battery, as shown in 
the charts and the following example. 

Example 

c. Open-circuit voltage = 12.0 V 

d. Charging time = 6.5 hours 

e. Charge of the battery = 20 ~ 30% 



3-52 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


<a 



c 

> 18 

Q) 17 

D) 

-2 16 
o 

> 15 

3 14 
"V 13 
o 12 
O 11 
10 


)hargin 


g 

Ambient temperature 20°C 




















































































































o 10 20 30 40 50 60 Time (minutes) 
L^ Check the open-circuit 
voltage. 



14 
> 13 

CD 
D) 
CO 

1 2 

> 

1 11 

1 10 
O 










Ambient 

temperature 

20°C 












































100 75 50 30 25 20 
Charging condition of the battery (%) 



5. Charge: 
• battery 
(refer to the appropriate charging method il- 
lustration) 



A WARNING 



Do not quick charge a battery. 



CAUTION: 



• Make sure that the battery vent is free of ob- 
structions. 

• Never remove the MF battery sealing caps. 
•Do not use a high-rate battery charger. 

They force a high-amperage current into 
the battery quickly and can cause battery 
overheating and battery plate damage. 

• If it is impossible to regulate the charging 
current on the battery charger, be careful 
not to overcharge the battery. 

• When charging a battery, be sure to remove 
it from the motorcycle. (If charging has to 
be done with the battery mounted on the 
motorcycle, disconnect the negative lead 
from the battery terminal.) 

•To reduce the chance of sparks, do not 
plug in the battery charger until the battery 
charger leads are connected to the battery. 

•Before removing the battery charger lead 
clips from the battery terminals, be sure to 
turn off the battery charger. 

• Make sure that the battery charger lead 
clips are in full contact with the battery ter- 
minal and that they are not shorted. A cor- 
roded battery charger lead clip may gener- 
ate heat in the contact area and a weak clip 
spring may cause sparks. 

• If the battery becomes hot to the touch at 
any time during the charging process, dis- 
connect the battery charger and let the bat- 
tery cool before reconnecting it. Hot batter- 
ies can explode! 

• As shown in the following illustration, the 
open-circuit voltage of a MF battery stabi- 
lizes about 30 minutes after charging has 
been completed. Therefore, wait 30 min- 
utes after charging is completed before 
measuring the open-circuit voltage. 



3-53 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


<& 



Charging method using a variable voltage charger 



Charger 




Measure the open-circuit 
voltage prior to charging. 



Connect a charged and 
AMP meter to the battery 
and start charging. 



YES 



I 



NOTE: 

Voltage should be measured 30 
minutes after the machine is stopped. 



NOTE: 



Make sure that the current 
is higher than the standard 
charging current written on 
the battery. 



Set the charging voltage at 1 6 ~ 17V 
(If the setting is lower, charging will be 
insufficient. If too high, the battery will 
be over-charged.) 



NO 



By turning the charging 
voltage adjust dial, set the 
charging voltage at 20 - 24 V. 



Adjust the voltage so that the 
current is at the standard 
charging level. 



YES 



I 



Monitor the amperage for 
3 — 5 minutes to check if the 
standard charging current is 
reached. 



Set the time according to the 
charging time suitable for the 
open-circuit voltage. 
Refer to "Battery condition 
checking steps". 



NO 



If the current does not 
exceed the standard 
charging current after 5 
minutes, replace the battery. 



If charging requires more than 5 hours, it is advisable to check the 
charging current after a lapse of 5 hours. If there is any change in the 
amperage, readjust the voltage to obtain the standard charging 
current. 



i 



Measure the battery open-circuit voltage after leaving the battery 

unused for more than 30 minutes. 

12.8 V or more — Charging is complete. 

12.7 V or less — Recharging is required. 

Under 12.0 V — Replace the battery. 



3-54 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


<& 



Charging method using a constant voltage charger 



Measure the open-circuit 
voltage prior to charging. 



NOTE: 

Voltage should be measured 30 
minutes after the machine is stopped. 



Connect a charger and 
AMP meter to the battery 
and start charging. 



YES 



Make sure that the current 
is higher than the standard 
charging current written on 
the battery. 



NO 



Charge the battery until the battery's 
charging voltage is 15 V. Charge the 
battery until the battery's charging 
voltage is 15 V. 



This type of battery charger cannot 
charge the MF battery. A variable 
voltage charger is recommended. 



NOTE: 

Set the charging time at 20 hours 
(maximum). 



Measure the battery open-circuit 

voltage after leaving the battery 

unused for more than 30 minutes. 

12.8 V or more — Charging is 

complete. 

12.7 V or less — Recharging is 

required. 

Under 1 2.0 V — Replace the battery. 



Charger 



AMP meter 




3-55 



CHECKING AND CHARGING THE BATTERY/ 

CHECKING THE FUSES 

6. Check: 

• battery vent 
Obstruction -k Clean. 
Damage -k Replace. 

7. Install: 

• battery 



CHK 
ADJ 


<a 





8. Connect: 
• battery leads 
(to the battery terminals) 

CAUTION: 



First, connect the positive lead ® , then the 
negative lead (2). 

9. Check: 
•battery terminals 

Dirt — ► Clean with a wire brush. 
Loose connection -► Connect properly. 

10. Lubricate: 
•battery terminals 



Recommended lubricant 
Dielectric grease 



11. Install: 
•seat 

EAS00181 

CHECKING THE FUSES 

The following procedure applies to all of the 
fuses. 

CAUTION: 



To avoid a short circuit, always turn the main 
switch to "OFF" when checking or replacing 
a fuse. 

1. Remove: 
•seat 

2. Check: 
•fuse 

a. Connect the pocket tester to the fuse and 
check the continuity. 

NOTE: 

Set the pocket tester selector to "£l x 1 ". 



3-56 



CHECKING THE FUSES 



CHK 
ADJ 


<a 



y- 


Pocket tester 
90890-03112 


b. If the pocket tester indicates "oo" 
fuse. 


, replace the 


3. Replace: 
•blown fuse 



a. Turn off the ignition. 

b. Install a new fuse of the correct amperage 
rating. 

c. Turn on the switches to verify if the electrical 
circuit is operational. 

d. If the fuse immediately blows again, check 
the electrical circuit. 



Fuses 


Amperage rating 


Quantity 


Main fuse 


30A 




Headlight fuse 


20A 




Signaling 
system fuse 


20A 




Ignition fuse 


20A 




Turn signal 
relay fuse 


10A 




Digital clock 
fuse 


10A 




Radiator fan 
fuse 


10A 




Reserve fuse 


30A 




Reserve fuse 


20 A 




Reserve fuse 


10A 








A WARNING 


Never use a fus 
other than that s 
ing a fuse with 1 


e with an ampere 
pecified. Improvis 
he wrong amper< 


ige rating 
;ingorus- 
ige rating 



may cause extensive damage to the electri- 
cal system, cause the lighting and ignition 
systems to malfunction and could possibly 
cause a fire. 

4. Install: 
•seat 



3-57 



REPLACING THE HEADLIGHT BULBS 



CHK 
ADJ 


<a 




REPLACING THE HEADLIGHT BULBS 

The following procedure applies to both of the 
headlight bulbs. 
1. Disconnect: 

•headlight coupler® 

•bulb cover (2) 



2. Remove: 
•headlight bulb holder® 

3. Remove: 
•headlight bulb (2) 



A WARNING 



Since the headlight bulb gets extremely hot, 
keep flammable products and your hands 
away from the bulb until it has cooled down. 

4. Install: ^^ 

•headlight bulb BBS 

Secure the new headlight bulb with the head- 
light bulb holder. 

CAUTION: 



Avoid touching the glass part of the head- 
light bulb to keep it free from oil, otherwise 
the transparency of the glass, the life of the 
bulb and the luminous flux will be adversely 
affected. If the headlight bulb gets soiled, 
thoroughly clean it with a cloth moistened 
with alcohol or lacquer thinner. 

5. Install: 
•headlight bulb holder 

6. Install: 
•bulb cover 

7. Connect: 
•headlight coupler 



3-58 



ADJUSTING THE HEADLIGHT BEAMS/ 
ADJUSTING THE DIGITAL CLOCK 



CHK 
ADJ 


<a 




EAS00185 

ADJUSTING THE HEADLIGHT BEAMS 

The following procedure applies to both of the 
headlights. 
1. Adjust: 
•headlight beam (vertically) 

a. Turn the adjusting screw ® in direction ® or 



Direction (a) 


Headlight beam is raised. 


Direction (b) 


Headlight beam is lowered. 



2. Adjust: 
•headlight beam (horizontally) 

a. Turn the adjusting knob ® in direction (a) or 

Left headlight 



Direction (a) 


Headlight beam moves to 
the right. 


Direction (6) 


Headlight beam moves to 
the left. 



Right headlight 



Direction (a) 


Headlight beam moves to 
the left. 


Direction © 


Headlight beam moves to 
the right. 




EAS00187 

ADJUSTING THE DIGITAL CLOCK 
NOTE: 



This digital clock constantly displays the time. 



1. Adjust: 
•digital clock© 



a. Hold down the "RESET" button (2) and "SE- 
LECT" button (3). 

b. Push the "RESET" button (2) to set the hour. 
And push the "SELECT" button. 

c. Push the "RESET" button (2) to set the min- 
utes. And push the "SELECT" button. 

NOTE: 

When setting the time (e.g., after reconnecting 
the battery), first set the clock to 1 :00 AM, then 
set it to the correct time. 



3-59 




CHAPTER 4 
CHASSIS 

FRONT WHEEL AND BRAKE DISCS 4-1 

FRONT WHEEL 4-2 

REMOVING THE FRONT WHEEL 4-3 

DISASSEMBLING THE FRONT WHEEL 4-3 

CHECKING THE FRONT WHEEL 4-4 

CHECKING THE BRAKE DISCS 4-5 

ASSEMBLING THE FRONT WHEEL 4-6 

INSTALLING THE FRONT WHEEL 4-7 

ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7 

REAR WHEEL AND BRAKE DISC 4-9 

REAR WHEEL 4-9 

REMOVING THE REAR WHEEL 4-12 

CHECKING THE REAR WHEEL 4-13 

CHECKING THE REAR WHEEL DRIVE HUB 4-13 

CHECKING AND REPLACING THE REAR WHEEL SPROCKET . 4-13 

CHECKING THE BRAKE DISC 4-14 

INSTALLING THE REAR WHEEL 4-15 

ADJUSTING THE REAR WHEEL STATIC BALANCE 4-15 

FRONT AND REAR BRAKES 4-16 

FRONT BRAKE PADS 4-16 

REPLACING THE FRONT BRAKE PADS 4-18 

REPLACING THE REAR BRAKE PADS 4-20 

FRONT BRAKE MASTER CYLINDER 4-23 

REAR BRAKE MASTER CYLINDER 4-25 

DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER .... 4-27 

DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-27 

CHECKING THE FRONT AND REAR BRAKE MASTER 

CYLINDERS 4-28 

ASSEMBLING AND INSTALLING THE FRONT BRAKE 

MASTER CYLINDER 4-29 

ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-31 

FRONT BRAKE CALIPERS 4-33 

REAR BRAKE CALIPER 4-35 

DISASSEMBLING THE FRONT BRAKE CALIPERS 4-37 

DISASSEMBLING THE REAR BRAKE CALIPER 4-38 

CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-39 

ASSEMBLING AND INSTALLING THE FRONT BRAKE 

CALIPERS 4-40 

ASSEMBLING AND INSTALLING THE REAR BRAKE 

CALIPER 4-42 




FRONT FORK 4-44 

REMOVING THE FRONT FORK LEGS 4-46 

DISASSEMBLING THE FRONT FORK LEGS 4-46 

CHECKING THE FRONT FORK LEGS 4-48 

ASSEMBLING THE FRONT FORK LEGS 4-49 

INSTALLING THE FRONT FORK LEGS 4-53 

HANDLEBAR 4-54 

REMOVING THE HANDLEBAR 4-55 

CHECKING THE HANDLEBAR 4-55 

INSTALLING THE HANDLEBAR 4-56 

STEERING HEAD 4-58 

REMOVING THE LOWER BRACKET 4-59 

CHECKING THE STEERING HEAD 4-59 

INSTALLING THE STEERING HEAD 4-60 

REAR SHOCK ABSORBER ASSEMBLY 4-61 

HANDLING THE REAR SHOCK ABSORBER AND 

GAS CYLINDER 4-62 

DISPOSING OF A REAR SHOCK ABSORBER AND 

GAS CYLINDER 4-62 

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-63 

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-64 

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-64 

SWINGARM AND DRIVE CHAIN 4-65 

REMOVING THE SWINGARM 4-67 

REMOVING THE DRIVE CHAIN 4-68 

CHECKING THE SWINGARM 4-68 

CHECKING THE DRIVE CHAIN 4-69 

INSTALLING THE DRIVE CHAIN 4-71 

INSTALLING THE SWINGARM 4-71 



FRONT WHEEL AND BRAKE DISCS 




CHASSIS 
FRONT WHEEL AND BRAKE DISCS * 



XI 72 Nm (7.2 nvkg) 




18Nm(1.8m«kg) 



Order 


Job/ Part 


Q'ty 


Remarks 


1 
2 
3 
4 
5 
6 
7 
8 


Removing the front wheel and brake 
discs 

Brake hose holder (left and right) 

Brake caliper (left and right) 

Wheel axle pinch bolt 

Front wheel axle 

Front wheel 

Collar (left and right) 

Oil seal cover (left and right) 

brake disc (left and right) 


2 
2 
1 
1 
1 
2 
2 
2 


Remove the parts in the order listed. 

NOTE: 

Place the motorcycle on a suitable stand 

so that the front wheel is elevated. 


Loosen. 

For installation, reverse the removal 
procedure. 



4-1 



FRONT WHEEL AND BRAKE DISCS 




FRONT WHEEL 




Order 


Job/ Part 


Q'ty 


Remarks 


® 


Disassembling the front wheel 

Oil seal (left and right) 
Wheel bearing (left and right) 
Spacer 


2 
2 

1 


Disassemble the parts in the order listed. 

For assembly, reverse the disassembly 
procedure. 



4-2 



FRONT WHEEL AND BRAKE DISCS 




EAS00521 

REMOVING THE FRONT WHEEL 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 



NOTE: 

Place the motorcycle on a suitable stand so that 
the front wheel is elevated. 



2. Remove: 

•left brake caliper 
•right brake caliper 

NOTE: 

Do not squeeze the brake lever when removing 
the brake calipers. 

3. Elevate: 
•front wheel 

NOTE: 

Place the motorcycle on a suitable stand so that 
the front wheel is elevated. 




DISASSEMBLING THE FRONT WHEEL 

1. Remove: 
•oil seals 
•wheel bearings 

a. Clean the outside of the front wheel hub. 

b. Remove the oil seals ® with a flat-head 
screwdriver. 

NOTE: 

To prevent damaging the wheel, place a rag (2) 
between the screwdriver and the wheel surface. 



c. Remove the wheel bearings with a general 
bearing puller. 



4-3 



FRONT WHEEL AND BRAKE DISCS 





n~i 


A 


emit 


) 






LM 


12010701 




EAS00525 

CHECKING THE FRONT WHEEL 

1. Check: 
•wheel axle 
Roll the wheel axle on a flat surface. 
Bends -+ Replace. 



A WARNING 



Do not attempt to straighten a bent wheel 
axle. 



2. Check: 

•tire 

•front wheel 
Damage/wear -► Replace. 
Refer to "CHECKING THE TIRES" and 
"CHECKING THE WHEELS" in chapter 3. 



© 


\ 

^ 


-o© 




U 


12010402 




Pa 




(i%i 




\LS J t 


m0 



3. Measure: 
•front wheel radial runout® 
•front wheel lateral runout (2) 
Over the specified limits -► Replace. 




Front wheel radial runout limit 

1 mm 
Front wheel lateral runout limit 

0.5 mm 



4. Check: 
•wheel bearings 

Front wheel turns roughly or is loose 

place the wheel bearings, 
•oil seals 

Damage/wear -+ Replace. 



Re- 



5. Replace: 
•wheel bearings 
•oil seals 



a. Clean the outside of the front wheel hub. 

b. Remove the oil seals ® with a flat-head 
screwdriver. 

NOTE: 

To prevent damaging the wheel, place a rag (2) 
between the screwdriver and the wheel surface. 



4-4 



FRONT WHEEL AND BRAKE DISCS 





c. Remove the wheel bearings (3) with a gener- 
al bearing puller. 

d. Install the new wheel bearings and oil seals 
in the reverse order of disassembly. 



CAUTION: 



Do not contact the wheel bearing center race 
® or balls (2). Contact should be made only 
with the outer race (3). 

NOTE: 

Use a socket (4) that matches the diameter of 
the wheel bearing outer race and oil seal. 




CHECKING THE BRAKE DISCS 

The following procedure applies to all of the 
brake discs. 

1. Check: 
•brake disc 

Damage/galling -► Replace. 

2. Measure: 

•brake disc deflection 

Out of specification -► Correct the brake disc 
deflection or replace the brake disc. 




Brake disc deflection limit 
(maximum) 
0.1 mm 



a. Place the motorcycle on a suitable stand so 
that the wheel is elevated. 

b. Before measuring the front brake disc deflec- 
tion, turn the handlebar to the left or right to 
ensure that the front wheel is stationary. 

c. Remove the brake caliper. 

d. Hold the dial gauge at a right angle against 
the brake disc surface. 

e. Measure the deflection 2 — 3 mm below the 
edge of the brake disc. 



4-5 



FRONT WHEEL AND BRAKE DISCS 








I 


) — 


p 




/ i 




— i(pin 






^Ci^c 


1 












12210501 
_ \ 




3. Measure: 
• brake disc thickness 
Measure the brake disc thickness at a few 
different locations. 
Out of specification -► Replace. 




Brake disc thickness limit 
(minimum) 
4.5 mm 



4. Adjust: 
•brake disc deflection 



a. Remove the brake disc. 

b. Rotate the brake disc by one bolt hole. 

c. Install the brake disc. 



NOTE: 

Tighten the brake disc bolts in stages and in a 
crisscross pattern. 



V 



Brake disc bolt 
18Nm(1.8irrkg) 
LOCTITE® 



d. Measure the brake disc deflection. 

e. If out of specification, repeat the adjustment 
steps until the brake disc deflection is within 
specification. 

f . If the brake disc deflection cannot be brought 
within specification, replace the brake disc. 




ASSEMBLING THE FRONT WHEEL 

1. Install: 
•wheel b earings 
•oil seals f 



a. Install the new wheel bearings and oil seals 
in the reverse order of disassembly. 



CAUTION: 



Do not contact the wheel bearing inner race 
® or balls (2) . Contact should be made only 
with the outer race (3). 

NOTE: 

Use a shocket (4) that matches the diameter of 
the wheel bearing outer race and oil seal. 



4-6 



FRONT WHEEL AND BRAKE DISCS 




EAS00544 

INSTALLING THE FRONT WHEEL 

The following procedure applies to both brake 

discs. 

1. Lubricate: 

•wheel axle 

•oil seal lips 



Recommended lubricant 
Lithium soap base grease 





\SB 





2. Tighten: 
•wheel axle® 



•wheel axle pinch bolt (2) 
CAUTION: 



XI 72 Nm (7.2 nvkg) 



23 Nm (2.3 nvkg) 



Before tightening the wheel axle nut, push 
down hard on the handlebar several times and 
check if the front fork rebounds smoothly. 



3. Install: 
•brake caliper 



XI 40 Nm ( 4 -0 m«kg7 



A WARNING 



Make sure that the brake hose is routed 
properly. 



ADJUSTING THE FRONT WHEEL STATIC 
BALANCE 

NOTE: 

• After replacing the tire, wheel or both, the front 
wheel static balance should be adjusted. 

•Adjust the front wheel static balance with the 
brake discs installed. 



1. Remove: 
•balancing weight(-s) 

NOTE: 

Place the front wheel on a suitable balancing 
stand. 



4-7 



FRONT WHEEL AND BRAKE DISCS 





w 


12010104 




2. Find: 
•front wheel's heavy spot 



a. Spin the front wheel. 

b. When the front wheel stops, put an "X-| " mark 
at the bottom of the wheel. 

c. Turn the front wheel 90 ° so that the "X-| " mark 
is positioned as shown. 

d. Release the front wheel. 

e. When the wheel stops, put an "X 2 " mark at 
the bottom of the wheel. 

f. Repeat steps (b) through (d) several times 
until all the marks come to rest at the same 
spot. 

g. The spot where all the marks come to rest is 
the front wheel's heavy spot "X". 



3. Adjust: 
•front wheel static balance 



a. Install a balancing weight® onto the rim ex- 
actly opposite the heavy spot "X". 

NOTE: 

Start with the lightest weight. 

b. Turn the front wheel 90° so that the heavy 
spot is positioned as shown. 

c. If the heavy spot does not stay in that posi- 
tion, install a heavier weight. 

d. Repeat steps (b) and (c) until the front wheel 
is balanced. 

4. Check: 
•front wheel static balance 

a. Turn the front wheel and make sure that it 
stays at each position shown. 

b. If the front wheel does not remain stationary 
at all of the positions, rebalance it. 



4-8 



REAR WHEEL AND BRAKE DISC 




REAR WHEEL AND BRAKE DISC 

REAR WHEEL 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the rear wheel 




Remove the parts in the order listed. 
NOTE: 


1 
2 
3 


Brake caliper 
Brake torque rod 
Nut 




Place the motorcycle on a suitable stand 
so that the rear wheel is elevated. 


Loosen. 


4 


Washer 






5 


Wheel axle 






6 


Rear wheel assembly 




For installation, reverse the removal 
procedure. 



4-9 



REAR WHEEL AND BRAKE DISC 





Order 


Job/Part 


Q'ty 


Remarks 




Disassembling the rear wheel 




Disassemble the parts in the order listed. 


® 


Spacer 






(2) 


Bearing 






(D 


Spacer 






® 


Oil seal 






® 


Circlip 






(D 


Bearing 




For assembly, reverse the disassembly 
procedure. 



4-10 



REAR WHEEL AND BRAKE DISC 




XI 18Nm(1.8m«kg) 




XI 69 Nm (6.9 m*kg) 



Order 


Job/ Part 


Q'ty 


Remarks 


1 


Removing the brake disc and rear 
wheel sprocket 

Brake disc 


1 


Remove the parts in the order listed. 


2 
3 

4 


Rear wheel sprocket 
Collar (left and right) 
Oil seal 


1 
2 
1 




5 
6 


Bearing 

Rear wheel drive hub 


1 
1 




7 


Rear wheel drive hub damper 


6 


For installation, reverse the removal 
procedure. 



4-11 



REAR WHEEL AND BRAKE DISC 




EAS00561 

REMOVING THE REAR WHEEL 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 




NOTE: 

Place the motorcycle on a suitable stand so that 
the rear wheel is elevated. 



2. Remove: 
•brake caliper® 

NOTE: 

Do not depress the brake pedal when removing 
the brake caliper. 



3. Loosen: 
•locknut® 
•adjusting nut (2) 

4. Remove: 
•wheel axle nut (3) 
•wheel axle 
•rear wheel 

NOTE: 

Push the rear wheel forward and remove the 
drive chain from the rear wheel sprocket. 



\ 


7\L 


4H 

1TO 


\ 



Remove: 
•left collar® 
» rear wheel drive hub (2) 
» rear wheel drive hub damper 
•right collar 



4-12 



REAR WHEEL AND BRAKE DISC 




CHECKING THE REAR WHEEL 

1. Check: 
•wheel axle 
•rear wheel 
•wheel bearings 
•oil seals 

Refer to "FRONT WHEEL". 

2. Check: 
•tire 
•rear wheel 

Damage/wear -+ Replace. 

Refer to "CHECKING THE TIRES" and 

"CHECKING THE WHEELS" in chapter 3. 

3. Measure: 

•rear wheel radial runout 
•rear wheel lateral runout 
Refer to "FRONT WHEEL". 




CHECKING THE REAR WHEEL DRIVE HUB 

1. Check: 

• rear wheel drive hub ® 
Cracks/damage -► Replace. 

• rear wheel drive hub dampers (2) 
Damage/wear -► Replace. 



CD 

/"V\ \ 
/ / \ 1 

/ I * 

I V \ / 

i \ \ y 


® 


12560103 




CHECKING AND REPLACING THE REAR 
WHEEL SPROCKET 

1. Check: 

• rear wheel sprocket 

More than 1 1 A tooth® wear -► Replace the 

rear wheel sprocket. 

Bent teeth -► Replace the rear wheel sprocket. 

(B) Correct 

(T) Drive chain roller 

(2) Rear wheel sprocket 

2. Replace: 

• rear wheel sprocket 

a. Remove the self-locking nuts and the rear 
wheel sprocket. 

b. Clean the rear wheel drive hub with a clean 
cloth, especially the surfaces that contact the 
sprocket. 

c. Install the new rear wheel sprocket. 



4-13 



REAR WHEEL AND BRAKE DISC 



V 




Rear wheel sprocket self-locking 
nut 

69 Nm (6.9 nrkg) 



NOTE: 

Tighten the self-locking nuts in stages and in a 
crisscross pattern. 




CHECKING THE BRAKE DISC 

1. Check: 
•brake disc 

Damage/galling -► Replace. 

2. Measure: 

•brake disc deflection 

Out of specification -► Correct the brake disc 
deflection or replace the brake disc. 




Brake disc deflection limit 
(maximum) 
0.1 mm 



a. Place the motorcycle on a suitable stand so 
that the wheel is elevated. 

b. Before measuring the front brake disc deflec- 
tion, turn the handlebar to the left or right to 
ensure that the front wheel is stationary. 

c. Remove the brake caliper. 

d. Hold the dial gauge at a right angle against 
the brake disc surface. 

e. Measure the deflection 2 — 3 mm below the 
edge of the brake disc. 







p 


) 




p 




/ I 




— I(plj~ 






aJ^-C 


I 














12210501 
— ^. 



Measure: 

►brake disc thickness 

Measure the brake disc thickness at a few 
different locations. 
Out of specification -► Replace. 




Brake disc thickness limit 
(minimum) 
4.5 mm 



4-14 



REAR WHEEL AND BRAKE DISC 





4. Adjust: 
•brake disc deflection 



a. Remove the brake disc. 

b. Rotate the brake disc by one bolt hole. 

c. Install the brake disc. 

NOTE: 

Tighten the brake disc bolts in stages and in a 
crisscross pattern. 



X 



Brake disc bolt 
18Nm(1.8rrrkg) 
LOCTITE® 



d. Measure the brake disc deflection. 

e. If out of specification, repeat the adjustment 
steps until the brake disc deflection is within 
specification. 

f . If the brake disc deflection cannot be brought 
within specification, replace the brake disc. 



INSTALLING THE REAR WHEEL 

1. Lubricate: 
•wheel axle 
•wheel bearings 
•oil seal lips 



Recommended lubricant 
Lithium soap base grease 



Tighten: 
►wheel axle nut 
►brake caliper bolts 



150Nm(15m«kg) 



40 Nm (4.0 rtvkg) 



ADJUSTING THE REAR WHEEL STATIC 
BALANCE 



NOTE: 

•After replacing the tire, wheel or both, the rear 
wheel static balance should be adjusted. 

•Adjust the rear wheel static balance with the 
brake disc and rear wheel drive hub installed. 



1. Adjust: 
• rear wheel static balance 
Refer to "FRONT WHEEL". 



4-15 



FRONT AND REAR BRAKES 




FRONT AND REAR BRAKES 

FRONT BRAKE PADS 




Order 


Job/ Part 


Q'ty 


Remarks 




Removing the front brake pads 




Remove the parts in the order listed. 


1 


Brake pad clip 


2 




2 


Brake pad pin 


1 




3 


Brake pad spring 


1 




4 


brake pad 


2 




5 


Brake pad shim 


2 




6 


Bleed scrw 


1 


For installation, reverse the removal 
procedure. 



4-16 



FRONT AND REAR BRAKES 





"XI 40 Nm (4.0 m»kg7 




Order 


Job/ Part 


Q'ty 


Remarks 




Removing the rear brake pads 




Remove the parts in the order listed. 


1 


Brake pad clip 


4 




2 


Brake pad pin 


2 




3 


Brake pad spring 


1 




4 


Brake pad 


2 




5 


Brake pad shim 


2 




6 


Bleed screw 


2 


For installation, reverse the removal 
procedure. 



4-17 



FRONT AND REAR BRAKES 




CAUTION: 



Disc brake components rarely require dis- 
assembly. 

Therefore, always follow these preventive 
measures: 

• Never disassemble brake components un- 
less absolutely necessary. 

• If any connection on the hydraulic brake 
system is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after reas- 
sembly. 

• Never use solvents on internal brake com- 
ponents. 

• Use only clean or new brake fluid for clean- 
ing brake components. 

• Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt fluid immediately. 

• Avoid brake fluid coming into contact with 
the eyes as it can cause serious injury. 

First aid for brake fluid entering the eyes: 

• Flush with water for 1 5 minutes and get im- 
mediate medical attention. 



REPLACING THE FRONT BRAKE PADS 

The following procedure applies to both brake 
calipers. 

NOTE: 

When replacing the brake pads, it is not neces- 
sary to disconnect the brake hose or disas- 
semble the brake caliper. 




1. Remove: 
•brake hose holder® 
•brake caliper® 



4-18 



FRONT AND REAR BRAKES 





£ 



^ 



^ 



2 



12220404 




2. Remove: 
•brake pad clips® 
•brake pad pins (2) 
•brake pad spring® 



3. Remove: 
• brake pads ® 
(along with the brake pad shims) 



4. Measure: 
•brake pad wear limit 
Out of specification 
pads as a set. 



Replace the brake 




Brake pad wear limit 
0.5 mm 



5. Install: 
•brake pad shims 

(onto the brake pads) 
• brake pads 
•brake pad spring 

NOTE: 

Always install new brake pads, brake pad 
shims, and a brake pad spring as a set. 



//} 


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// 








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q) \\y. 


W\ \ 




M 





a. Connect a clear plastic hose ® tightly to the 
bleed screw (2). Put the other end of the hose 
into an open container. 

b. Loosen the bleed screw and push the brake 
caliper pistons into the brake caliper with 
your finger. 

c. Tighten the bleed screw. 



X 



% 



Bleed screw 

6 Nm (0.6 rrvkg) 



4-19 



FRONT AND REAR BRAKES 





d. Install new brake pad shims onto the new 
brake pads. 

e. Install new brake pads and a new brake pad 
spring. 

NOTE: 

The arrow® on the brake pad spring must point 
in the direction of disc rotation. 



6. Install: 

• brake pad cover 
•brake pad pins 
•brake pad clips 
•brake caliper 

7. Check: 
•brake fluid level 



40 Nm (4.0 rrvkg) 



Below the minimum level mark® — ► Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 
8. Check: 
• brake lever operation 
Soft or spongy feeling -► Bleed the brake 
system. 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 




REPLACING THE REAR BRAKE PADS 
NOTE: 

When replacing the brake pads, it is not neces- 
sary to disconnect the brake hose or disas- 
semble the brake caliper. 



1. Remove: 
•brake caliper® 

2. Remove: 
•brake pad clips® 
•brake pad pins© 
•brake pad spring® 
• brake pads 

(along with the brake pad shims) 



4-20 



FRONT AND REAR BRAKES 





3. Measure: 
•brake pad wear limit 
Out of specification 
pads as a set. 



Replace the brake 




Brake pad wear limit 
0.5 mm 



4. Install: 
•brake pad shims 

(onto the brake pads) 
• brake pads 
•brake pad spring 

NOTE: 



Always install new brake pads, brake pad 
shims, brake pad pins, brake pad clips, and a 
brake pad spring as a set. 






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(3) 


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c 




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d 




:> 









a. Connect a clear plastic hose ® tightly to the 
bleed screw®. Put the other end of the hose 
into an open container. 

b. Loosen the bleed screw and push the brake 
caliper pistons into the brake caliper with 
your finger. 

c. Tighten the bleed screw. 



X 



Bleed screw 

6 Nm (0.6 rrvkg) 



d. Install a new brake pad shim (3) onto each 
new brake pad®. 

e. Install new brake pads and a new brake pad 
spring. 



4-21 



FRONT AND REAR BRAKES 



Install: 

► brake pad cover 
►brake pad pins 
►brake pad clips 
►brake caliper 




"XI 40 Nm (4.0 rrvkgY 




6. Check: 
•brake fluid level 

Below the minimum level mark® — ► Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 

7. Check: 

• brake lever operation 
Soft or spongy feeling -► Bleed the brake 
system. 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 



4-22 



FRONT AND REAR BRAKES 



EAS00584 

FRONT BRAKE MASTER CYLINDER 





XI 10Nm(1.0nrrkg) 



XI 30 Nm (3.0 nvkg) 



Order 


Job/ Part 


Q'ty 


Remarks 




Removing the front brake master 
cylinder 

Brake fluid 




Remove the parts in the order listed. 
Drain. 


1 


Brake lever 


1 




2 


Brake switch lead 


2 




3 


Brake switch 


1 




4 
5 
6 

7 


Union bolt 

Brake hose/copper washer 
Master cylinder bracket 
Master cylinder 


1 - 
1/2 
1 
1 - 


" Refer to "REMOVING/ASSEMBLING 
AND INSTALLING THE FRONT BRAKE 
MASTER CYLINDER" section. 

For installation, reverse the removal 
procedure. 



4-23 



FRONT AND REAR BRAKES 





Order 


Job/ Part 


Q'ty 


Remarks 




Disassembling the front brake 




Disassemble the parts in the order listed. 




master cylinder 






© 


Master cylinder boot 


1 




(2) 


Circlip 


1 




(D 


Master cylinder kit 


1 




® 


Spring 


1 


For assembly, reverse the disassembly 
procedure. 



4-24 



FRONT AND REAR BRAKES 



EAS00586 

REAR BRAKE MASTER CYLINDER 




~\| 4 Nm (0.4 m«kg)~ 




23 Nm (2.3 m«kg) 



Order 


Job/ Part 


Q'ty 


Remarks 




Removing the rear brake master 




Remove the parts in the order listed. 




cylinder 








Side cover (right) 








Brake fluid 




Drain. 


1 


Master cylinder bolt 


2 




2 


Union bolt 


1 - 


-. Refer to "REMOVING/ASSEMBLING 
J AND INSTALLING THE REAR BRAKE 


3 


Brake hose/copper washer 


1/2- 








MASTER CYLINDER" section. 


4 


Clip/hose 


2/1 




5 


Cotter pin 


1 




6 


Pin 


1 




7 


Washer 


1 




8 


Master cylinder 


1 


For installation, reverse the removal 
procedure. 



4-25 



FRONT AND REAR BRAKES 





Order 


Job/ Part 


Q'ty 


Remarks 




Disassembling the rear brake master 




Disassemble the parts in the order listed. 




cylinder 






© 


Master cylinder boot 


1 




© 


Circlip 


1 




(D 


Master cylinder kit 


1 




® 


Spring 


1 


For assembly, reverse the disassembly 
procedure. 



4-26 



FRONT AND REAR BRAKES 




DISASSEMBLING THE FRONT BRAKE MAS- 
TER CYLINDER 

NOTE: 

Before disassembling the front brake master 
cylinder, drain the brake fluid from the entire 
brake system. 




Disconnect: 
►brake switch coupler 

(from the brake switch) 

Remove: 
►union bolt® 
►copper washers® 
► brake hose (3) 



NOTE: 

To collect any remaining brake fluid, place a 
container under the master cylinder and the end 
of the brake hose. 



DISASSEMBLING THE REAR BRAKE MAS- 
TER CYLINDER 

1. Remove: 
•side cover (right) 




2. Remove: 
•union bolt® 
•copper washers® 
• brake hose (3) 

NOTE: 



To collect any remaining brake fluid, place a 
container under the master cylinder and the end 
of the brake hose. 



4-27 



FRONT AND REAR BRAKES 




Al 






Bj 




t^ 


"S 




H^g 




CHECKING THE FRONT AND REAR BRAKE 
MASTER CYLINDERS 

The following procedure applies to the both of 
the brake master cylinders. 

1. Check: 

•brake master cylinder 

Damage/scratches/wear -► Replace, 
•brake fluid delivery passages 

(brake master cylinder body) 

Obstruction -► Blow out with compressed air. 

H Front 
\B\ Rear 

2. Check: 

• brake master cylinder kit © 
Damage/scratches/wear -► Replace. 

[C| Front 
[D] Rear 



Check: 

►rear brake fluid reservoir© 
Cracks/damage -► Replace. 
► rear brake fluid reservoir diaphragm (2) 
Cracks/damage -► Replace. 



4. Check: 

•front brake master cylinder reservoir® 
Cracks/damage -+ Replace. 

•front brake master cylinder reservoir dia- 
phragm (2) 
Damage/wear -► Replace. 



5. Check: 
• brake hoses 
Cracks/damage/wear 



Replace. 



4-28 



FRONT AND REAR BRAKES 




EAS00598 

ASSEMBLING AND INSTALLING THE 
FRONT BRAKE MASTER CYLINDER 



A WARNING 



•Before installation, all internal brake com- 
ponents should be cleaned and lubricated 
with clean or new brake fluid. 

• Never use solvents on internal brake com- 
ponents. 



*fr 



Recommended brake fluid 
DOT 4 



1. Install: 
• brake master cylinder © 



10Nm(1.0nvkg) 




NOTE: 

•Install the brake master cylinder holder with 
the "UP" mark facing up. 

•Align the end of the brake master cylinder hold- 
er with the punch mark© on the handlebar. 

• First, tighten the upper bolt, then the lower bolt. 



2. Install: 
•copper washers® 



• brake hose © 
•union bolt® 

CAUTION: 



XI 30 Nm (3.0 nvkg) 



When installing the brake hose onto the 
brake master cylinder, make sure that the 
brake pipe touches the projection @ on the 
brake master cylinder. 



A WARNING 



Proper brake hose routing is essential to in- 
sure safe motorcycle operation. Refer to 
"CABLE ROUTING". 



NOTE: 

•While holding the brake hose, tighten the 

union bolt as shown. 
• Turn the handlebar to the left and to the right to 

make sure that the brake hose does not touch 

other parts (e.g., wire harness, cables, leads). 

Correct if necessary. 



4-29 



FRONT AND REAR BRAKES 




3. Fill: 
•brake master cylinder reservoir 
(with the specified amount of the recom- 
mended brake fluid) 



•Y> 



Recommended brake fluid 
DOT 4 



A WARNING 



• Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance. 

• Refill with the same type of brake fluid that 
is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor- 
mance. 

• When refilling, be careful that water does 
not enter the reservoir. Water will signifi- 
cantly lower the boiling point of the brake 
fluid and could cause vapor lock. 



CAUTION: 




Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 

4. Bleed: 

• brake system 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 

5. Check: 
•brake fluid level 

Below the minimum level mark® — ► Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 

6. Check: 

• brake lever operation 

Soft or spongy feeling -► Bleed the brake 

system. 

Refer to "BLEEDING THE HYDRAULIC 

BRAKE SYSTEM" in chapter 3. 



4-30 



FRONT AND REAR BRAKES 





EAS00608 

ASSEMBLING THE REAR BRAKE MASTER 
CYLINDER 

1. Install: 
•copper washers® 
• brake hose (2) 
•union bolt® 



30 Nm (3.0 m«kg) 



CAUTION: 



When installing the brake hose onto the 
brake master cylinder, make sure that the 
brake pipe touches the projection @ as 
shown. 



A WARNING 



Proper brake hose routing is essential to in- 
sure safe motorcycle operation. Refer to 
"CABLE ROUTING". 




2. Fill: 
•brake fluid reservoir 
(to the maximum level mark®) 



•ft 



Recommended brake fluid 
DOT 4 



A WARNING 



• Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance. 

• Refill with the same type of brake fluid that 
is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor- 
mance. 

• When refilling, be careful that water does 
not enter the reservoir. Water will signifi- 
cantly lower the boiling point of the brake 
fluid and could cause vapor lock. 



CAUTION: 



Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 



4-31 



FRONT AND REAR BRAKES 




3. Bleed: 
• brake system 
Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 



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(a\- 






OWER 


Wo 


^y 


L 




- 








Check: 

►brake fluid level 

Below the minimum level mark® — ► Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 



5. Adjust: 
• brake pedal position © 
Refer to "ADJUSTING THE REAR BRAKE" 
in chapter 3. 




Brake pedal position (below the 
top of the rider footrest) 
40 mm 



Adjust: 

►rear brake light operation timing 
Refer to "ADJUSTING THE REAR BRAKE 
LIGHT SWITCH" in chapter 3. 



4-32 



FRONT AND REAR BRAKES 




FRONT BRAKE CALIPERS 



XI 6Nm(0.6nvkg) 




30 Nm (3.0 m»kg) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the front brake calipers 

Brake fluid 




Remove the parts in the order listed. 
Drain. 


1 


Union bolt 


1 




2 
3 


Copper washer 
Brake hose 


2 

1 




4 


Brake caliper 


1 


For installation, reverse the removal 
procedure. 



4-33 



FRONT AND REAR BRAKES 





Order 


Job/ Part 


Q'ty 


Remarks 




Disassembling the front brake calipers 




Disassemble the parts in the order listed. 
The following procedure applies to both of 
the front brake calipers. 


(!) 


Brake pad clip 


2 




<D 


Brake pad pin 


1 




® 


Brake pad spring 


1 




(4) 


Brake pad 


2 




(5) 


Brake caliper piston 


4 




(6) 


Brake caliper piston seal 


8 




® 


Bleed screw 


1 


For assembly, reverse the disassembly 
procedure. 



4-34 



FRONT AND REAR BRAKES 




REAR BRAKE CALIPER 





XI 30 Nm (3.0 nvkg) 



40 Nm (4.0 rri'kg) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the rear brake caliper 

Brake fluid 




Remove the parts in the order listed. 
Drain. 


1 


Union bolt 


1 




2 
3 


Copper washer 
Brake hose 


2 

1 




4 


Brake caliper 


1 


For installation, reverse the removal 
procedure. 



4-35 



FRONT AND REAR BRAKES 




6 Nm (0.6 nvkg) 




Order 


Job/ Part 


Q'ty 


Remarks 




Disassembling the rear brake caliper 




Disassemble the parts in the order listed. 


CO 


Brake pad clip 


4 




<D 


Brake pad pin 


2 




(3) 


Brake pad spring 


1 




(4) 


Brake pad 


2 




(5) 


Brake caliper piston 


2 




(6) 


Brake caliper piston seal 


4 




® 


Bleed screw 


2 


For assembly, reverse the disassembly 
procedure. 



4-36 



FRONT AND REAR BRAKES 




EAS00625 

DISASSEMBLING THE FRONT BRAKE CAL- 
IPERS 

The following procedure applies to both of the 
brake calipers. 

NOTE: 

Before disassembling either brake caliper, drain 
the brake fluid from the entire brake system. 




1. Remove: 
•union bolt® 
•copper washers® 
• brake hose (3) 



NOTE: 

Put the end of the brake hose into a container 
and pump out the brake fluid carefully. 



2. Remove: 

• brake caliper pistons ® 

• brake caliper piston seals (2) 



a. Secure the right side brake caliper pistons 
with a piece of wood (a). 

b. Blow compressed air into the brake hose 
joint opening © to force out the left side pis- 
tons from the brake caliper. 



A WARNING 



• Never try to pry out the brake caliper pis- 
tons. 

• Do not loosen the bolts (3). 



c. Remove the brake caliper piston seals. 

d. Repeat the previous steps to force out the 
right side pistons from the brake caliper. 



4-37 



FRONT AND REAR BRAKES 




EAS00628 

DISASSEMBLING THE REAR BRAKE CAL- 
IPER 

NOTE: 

Before disassembling the brake caliper, drain 
the brake fluid from the entire brake system. 




1. Remove: 
•union bolt® 
•copper washers (2) 
• brake hose 



NOTE: 

Put the end of the brake hose into a container 
and pump out the brake fluid carefully. 



2. Remove: 

• brake caliper pistons ® 

• brake caliper piston seals (2) 



a. Secure the right side brake caliper piston 
with a piece of wood (a). 

b. Blow compressed air into the brake hose 
joint opening © to force out the left side pis- 
ton from the brake caliper. 



A WARNING 



• Never try to pry out the brake caliper pis- 
tons. 

• Do not loosen the bolts (3). 



c. Remove the brake caliper piston seals. 

d. Repeat the previous steps to force out the 
right side piston from the brake caliper. 



4-38 



FRONT AND REAR BRAKES 




CHECKING THE FRONT AND REAR BRAKE 
CALIPERS 



Recommended brake component 
replacement schedule 


Brake pads 


If necessary 


Piston seals 


Every two years 


Brake hoses 


Every two years 


Brake fluid 


Every two years 
and whenever the 
brake is disas- 
sembled. 




Replace the brake 



1. Check: 

• brake caliper pistons ® 
Rust/scratches/wear -► 
caliper. 

• brake caliper cylinders (2) 
Scratches/wear -► Replace the brake cali- 
per. 

•brake calipers 

Cracks/damage -► Replace, 
•brake fluid delivery passages 

(brake caliper body) 

Obstruction — ► Blow out with compressed Air. 



A WARNING 



Whenever a brake caliper Is disassembled, 
replace the brake caliper piston seals. 

El Front 
\E Rear 



2. Check: 
• brake caliper brackets ® 
Cracks/damage -► Replace. 



4-39 



FRONT AND REAR BRAKES 




EAS00638 

ASSEMBLING AND INSTALLING THE 
FRONT BRAKE CALIPERS 

The following procedure applies to both of the 
brake calipers. 



A WARNING 



•Before installation, all internal brake com- 
ponents should be cleaned and lubricated 
with clean or new brake fluid. 

• Never use solvents on internal brake com- 
ponents as they will cause the piston seals 
to swell and distort. 

• Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals. 



*fr 



Recommended brake fluid 
DOT 4 




1. Install: 
•brake caliper 
(temporarily) 
•copper washers® 
• brake hose (2) 
•union bolt (3) 



A WARNING 



30 Nm (3.0 m«kg) 



Proper brake hose routing is essential to in- 
sure safe motorcycle operation. Refer to 
"CABLE ROUTING". 

CAUTION: 



When installing the brake hose onto the 
brake caliper, make sure that the brake pipe 
® touches the projection © on the brake 
caliper. 



Remove: 
►brake caliper 

Install: 
► brake pads 
►brake pad pins 
►brake pad clips 
►brake hose holder 
►brake caliper 



Refer to "REPLACING THE BRAKE PADS' 



6 Nm (0.6 rrvkg) 



40 Nm (4.0 rrvkg) 



4-40 



FRONT AND REAR BRAKES 




4. Fill: 
•brake master cylinder reservoir 
(with the specified amount of the recom- 
mended brake fluid) 



•Y> 



Recommended brake fluid 
DOT 4 



A WARNING 



• Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance. 

• Refill with the same type of brake fluid that 
is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor- 
mance. 

• When refilling, be careful that water does 
not enter the reservoir. Water will signifi- 
cantly lower the boiling point of the brake 
fluid and could cause vapor lock. 



CAUTION: 




Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 

5. Bleed: 

• brake system 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 

6. Check: 
•brake fluid level 

Below the minimum level mark® — ► Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 

7. Check: 

• brake lever operation 

Soft or spongy feeling -► Bleed the brake 

system. 

Refer to "BLEEDING THE HYDRAULIC 

BRAKE SYSTEM" in chapter 3. 



4-41 



FRONT AND REAR BRAKES 




EAS00644 

ASSEMBLING AND INSTALLING THE REAR 
BRAKE CALIPER 



A WARNING 



•Before installation, all internal brake com- 
ponents should be cleaned and lubricated 
with clean or new brake fluid. 

• Never use solevents on internal brake com- 
ponents as they will cause the piston seals 
to swell and distort. 

• Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals. 





WML 




*fr 



Recommended brake fluid 
DOT 4 



1. Install: 
•brake caliper® 

(temporarily) 
•copper washers 
• brake hose (2) 
•union bolt® 



A WARNING 



30 Nm (3.0 rrvkg) 



Proper brake hose routing is essential to in- 
sure safe motorcycle operation. Refer to 
"CABLE ROUTING". 



CAUTION: 



When installing the brake hose onto the 
brake caliper, make sure that the brake pipe 
© touches the projection (b) on the brake 
caliper. 



Remove: 
►brake caliper 

Install: 
► brake pads 
►brake pad pin 
►brake pad clips 
►brake caliper 



"XI 40 Nm (4.0 m«kg7 



Refer to "REPLACING THE BRAKE PADS". 
Fill: 

►brake fluid reservoir 

(with the specified amount of the recom- 
mended brake fluid) 



•ft 



Recommended brake fluid 
DOT 4 



4-42 



FRONT AND REAR BRAKES 




A WARNING 



• Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance. 

• Refill with the same type of brake fluid that 
is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor- 
mance. 

• When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock. 

CAUTION: 



Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 

5. Bleed: 
• brake system 
Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 




6. Check: 
•brake fluid level 

Below the minimum level mark® — ► Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 

7. Check: 

• brake pedal operation 
Soft or spongy feeling -► Bleed the brake 
system. 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 



4-43 



FRONT FORK 




FRONT FORK 



23 Nm 




30 Nm (3.0 m«kg) 



3 | XI 25 Nm (2.5 nvkg) 



Order 


Job/ Part 


Q'ty 


Remarks 




Removing the front fork 

Front wheel 




Remove the parts in the order listed. 
Refer to "FRONT WHEEL AND BRAKE 
DISCS". 


1 


Front fender 


1 




2 
3 
4 
5 


Bolt (upper bracket) 

Cap bolt 

Bolt (lower bracket) 

Front fork assembly (left/right) 


2 
2 

4 
1/1 


Loosen. -, 
Loosen. 
Loosen. -I 

For installc 


Refer to "REMOVING/ 
INSTALLING THE FRONT 
FORK LEGS" section. 

ition, reverse the removal 








procedure. 



4-44 



FRONT FORK 





* 



3 

J® 



25 Nm (2.5 nvkg) 




I)|2S 



^® 



ILK 



8-^® 



u 





35 Nm (3.5 m»kg) 



Order 


Job/Part 


Q'ty 


Remarks 




Disassembly the front fork 




Disassemble the parts in the order listed. 


CD 


Cap bolt 






© 


O-ring 






® 


Spacer 






(4) 


Spring seat 






(5) 


Fork spring 






(6) 


Damper adjusting rod 






(7) 


Dust seal 






® 


Oil seal clip 






(9) 


Damper rod bolt 






© 


Copper washer 






(11) 


Damper rod 






© 


Inner tube 






© 


Oil seal 






® 


Washer 






© 


Slide metal 






© 


Oil flow stopper 




For assembly, reverse the disassembly 
procedure. 



4-45 



FRONT FORK 




EAS00649 

REMOVING THE FRONT FORK LEGS 

The following procedure applies to both of the 

front fork legs. 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 




NOTE: 

Place the motorcycle on a suitable stand so that 
the front wheel is elevated. 



2. Loosen: 
• upper bracket pinch bolt © 
•cap bolt® 
•lower bracket pinch bolt® 



A WARNING 



Before loosening the upper and lower 
bracket pinch bolts, support the front fork 
leg. 

3. Remove: 
•front fork leg 




DISASSEMBLING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 
1. Remove: 

•cap bolt® 
(from the damper adjusting rod) 

•nut(2) 

NOTE: 

Remove the cap bolt with the piston rod holder 



y- 



Piston rod holder 
90890-01434 



4-46 




FRONT FORK 




2. Remove: 
•spacer® 
•spring seat© 
•spring® 

•damper adjusting rod (4) 

3. Drain: 
•fork oil 



4. Remove: 
•oil seal clip® 
(with a flat-head screwdriver) 

CAUTION: 



Do not scratch the inner tube. 



5. Remove: 
•damper rod bolt 
•damper rod® 

NOTE: 



While holding the damper rod with the damper 
rod holder (2), loosen the damper rod bolt. 




Damper rod holder 
90890-01447 




Remove: 
•inner tube 



a. Hold the front fork leg horizontally. 

b. Securely clamp the brake caliper bracket in a 
vise with soft jaws. 

c. Separate the inner tube from the outer tube 
by pulling the inner tube forcefully but care- 
fully. 



4-47 



FRONT FORK 




CAUTION: 



•Excessive force will damage the oil seal 
and bushing. A damaged oil seal or bush- 
ing must be replaced. 

• Avoid bottoming the inner tube into the 
outer tube during the above procedure, as 
the oil flow stopper will be damaged. 




CHECKING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 
1. Check: 

•inner tube® 

•outer tube® 
Bends/damage/scratches -► Replace. 



A WARNING 



Do not attempt to straighten a bent inner 
tube as this may dangerously weaken it. 



2. Measure: 
•spring free length® 
Over the specified limit 



Replace. 




Spring free length limit 
347.0 mm 



3. Check: 

•damper rod 
Damage/wear -► Replace. 
Obstruction -► Blow out all of the oil pas- 
sages with compressed air. 

•oil flow stopper 
Damage -► Replace. 

CAUTION: 



• The front fork leg has a built-in damper ad- 
justing rod and a very sophisticated inter- 
nal construction, which are particularly 
sensitive to foreign material. 

• When disassembling and assembling the 
front fork leg, do not allow any foreign ma- 
terial to enter the front fork. 



4. Check: 
•cap bolt O-ring 
Damage/wear - 



Replace. 



4-48 



FRONT FORK 




ASSEMBLING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 



A WARNING 



• Make sure that the oil levels in both front 
fork legs are equal. 

• Uneven oil levels can result in poor han- 
dling and a loss of stability. 



NOTE: 

•When assembling the front fork leg, be sure to 

replace the following parts: 

-inner tube bushing 

-outer tube bushing 

-oil seal 

-dust seal 
•Before assembling the front fork leg, make 

sure that all of the components are clean. 




1. Install: 
•damper rod® 

CAUTION: 



Allow the damper rod to slide slowly down 
the inner tube (2) until it protrudes from the 
bottom of the inner tube. Be careful not to 
damage the inner tube. 



NOTE: 

Install the oil flow stopper with a flat surface part 
@ downward. 



2. Lubricate: 
• inner tube's outer surface 



Recommended lubricant 
Fork oil 5W or equivalent 



3. Tighten: 
• damper rod bolt ® |XI 35 Nm (3.5 m«kg) 



LOCTITE 



® 



NOTE: 

While holding the damper rod with the damper 
rod holder (2), tighten the damper rod bolt. 




Damper rod holder 
90890-01447 



4-49 




FRONT FORK 




4. Install: 
•oil seal® 
(with the fork seal driver weight (2) and fork 
seal driver attachemt (3)) 



P 



Fork seal driver weight 

90890-01367 
Fork seal driver attachment 

90890-01374 



CAUTION: 



Make sure that the numbered side of the oil 
seal faces up. 

NOTE: 

• Before installing the oil seal, apply lithium soap 
base grease onto its lips. 

• Apply fork oil onto the outer surface of the inner 
tube. 

•Before installing the oil seal, cover the top of 
the front fork leg with a plastic bag to protect 
the oil seal during installation. 

5. Install: 
•oil seal clip 

NOTE: 

Adjust the oil seal clip so that it fits into the outer 
tube's groove. 

6. Fill: 

•front fork leg 
(with the specified amount of the recom- 
mended fork oil) 



•tt 



Quantity (each front fork leg) 

0.44 L (440 cm 3 ) 
Recommended oil 

Yamaha suspension oil "01" or 

equivalent 



CAUTION: 



•Be sure to use the recommended fork oil. 
Other oils may have an adverse effect on 
front fork performance. 

• When disassembling and assembling the 
front fork leg, do not allow any foreign ma- 
terial to enter the front fork. 



NOTE: 

Be sure to bleed the front fork. 



4-50 



FRONT FORK 





7. Install: 
•rod puller® 
• rod puller attachment (2) 
(onto the damper rod (3)) 



P 



Rod puller 

90890-01437 
Rod puller attachment 

90890-01436 



8. After filling the front fork leg, slowly stroke the 
damper rod ® up and down (at least ten 
times) to distribute the fork oil. 

NOTE: 

Be sure to stroke the damper rod slowly be- 
cause the fork oil may spurt out. 



9. Slowly stroke the inner tube (2) up and down 
to distribute the fork oil once more (1 stroke = 
about 150 mm). 

NOTE: 

Be careful not to stroke the inner tube over 1 50 
mm as this will cause air to enter. If the inner 
tube is stroke more than 150 mm, repeat steps 
(10) and (11). 

10. Before checking the fork oil level, wait ten 
minutes until the oil has settled and the air 
bubbles have dispersed. 

NOTE: 

Be sure to bleed the front fork leg of any residual 
air. 











i 
1 


i 

1 


® 

12311403 

















11. Measure: 
•front fork leg oil level @ 
Out of specification -► Correct. 




Front fork leg oil level (from the 
top of the inner tube and damper 
rod, with the inner tube fully 
compressed, and without the 
spring) 
140 mm 



4-51 




FRONT FORK 




12. Install: 
•spring© 
•spring seats© 
•spacer® 
•nut® 

•damper adjusting rod (5) 
•cap bolt© 



11 


i ^ r 




r^ r) 


® 




r 


O O 

o o 


© 




71 


<J LJ 




a. Install the fork spring, spring seats, and 
spacer. 

NOTE: 

Install the fork spring with the larger pitch (a) fac- 
ing up. 

(6) smaller pitch 

b. Install the rod puller and the rod puller attach- 
ment onto the damper rod. 

c. Pull up the rod puller and install the rod hold- 
er (D between the rod puller attachment (2) 
and the spacer. 

NOTE: 

Use the side of the rod holder that is marked "B". 




Piston rod holder 
90890-01434 



d. Remove the rod puller and the rod puller at- 
tachment. 

e. Install the damper adjusting rod locknut. 

f. Tighten the damper adjusting rod locknut. 



V 



Damper adjusting rod locknut 
25 Nm (2.5 irrkg) 



g. Install the damper adjusting rod and cap bolt, 

and finger tighten it. 
h. Remove the rod holder. 

CAUTION: 



The spring is compressed. 



4-52 



FRONT FORK 




INSTALLING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 
1. Install: 
•front fork leg 

Temporarily tighten the upper and lower 

bracket pinch bolts. 

NOTE: 

Make sure that the inner fork tube is flush with 
the top of the handlebar holder. 




2. Tighten: 
•lower bracket pinch bolt® 



XI 23 Nm (2.3 m-kg) 


• cap bolt (2) X 25 Nm ( 2 - 5 m#k 9) 


• upper bracket pinch bolt (3) 


X 30 Nm (3.0 m-kg) 




A WARNING | 



Make sure that the brake hoses are routed 
properly. 

3. Adjust: 
•spring preload 
•rebound damping 
•compression damping 

Refer to "ADJUSTING THE FRONT FORK" 

in chapter 3. 



4-53 



HANDLEBAR 




HANDLEBAR 



23 Nm (2.3 nvkg) 




26 Nm (2.6 m»kg) 



Order 


Job/ Part 


Q'ty 


Remarks 


1 
2 
3 


Removing the handlebar 

Front brake master cylinder 
Right handlebar switch 
Throotle cable 




Remove the parts in the order listed. 


4 
5 
6 

7 
8 


Grip end (right) 

Throttle grip 

Grip end (left) 

Left grip 

Left handlebar switch 






9 


Starter cable 






10 


Clutch cable 






11 


Clutch lever 






12 


Handlebar holder 


2 




13 


Handlebar 


1 


For installation, reverse the removal 
procedure. 



4-54 



HANDLEBAR 




REMOVING THE HANDLEBAR 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 






Ar^-^V 








( ^A 12410201 





2. Remove: 
•throttle cable housing ® 
•throttle grip (2) 



3. Remove: 
•handlebar grip® 

NOTE: 



Blow compressed air between the handlebar 
and the handlebar grip, and gradually push the 
grip off the handlebar. 



CHECKING THE HANDLEBAR 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 




2. Check: 
•handlebar 
Bends/cracks/damage -► Replace. 



A WARNING 



Do not attempt to straighten a bent handle- 
bar as this may dangerously weaken it. 



4-55 



HANDLEBAR 




3. Install: 
•handlebar grip 



a. Apply a light coat of rubber adhesive onto the 
left end of the handlebar. 

b. Slide the handlebar grip over the left end of 
the handlebar. 

c. Wipe off any excess rubber adhesive with a 
clean rag. 



A WARNING 



Do not touch the handlebar grip until the 
rubber adhesive has fully dried. 



INSTALLING THE HANDLEBAR 

1 . Stand the motorcycle on a level surface. 



A WARNING 




Securely support the motorcycle so that 
there is no danger of it falling over. 

2. Install: 
•handlebar® 
• upper handlebar holders (2) 



XI 23 Nm (2.3 nvkg) 



CAUTION: 



•First, tighten the bolts on the front side of 
the handlebar holder, then on the rear side. 

• Turn the handlebar all the way to the left 
and right. If there is any contact with the 
fuel tank, adjust the handlebar position. 



NOTE: 

Align the match marks (a) in the handlebar with 
the upper surface of the lower handlebar hold- 
ers. 




3. Install: 
•throttle grip® 
•throttle cables 

NOTE: 



Align the pins ® on the right handlebar switch 
with the holes® in the handlebar. 



4-56 



HANDLEBAR 





5. Install: 
• left handlebar switch 

NOTE: 



Align the pins (a) on the right handlebar switch 
with the holes © in the handlebar. 



6. Install: 
•clutch lever holder 

NOTE: 



Align the slit in the clutch lever holder with the 
punch mark® in the left handlebar. 

7. Install: 

•brake master cylinder 
Refer to "ASSEMBLING AND INSTALLING 
THE FRONT BRAKE MASTER CYL- 
INDER". 

8. Adjust: 

•throttle cable free play 
Refer to "ADJUSTING THE THROTTLE 
CABLE FREE PLAY" in chapter 3. 




Throttle cable free play (at the 
flange of the throttle grip) 
3 — 5 mm 



4-57 



STEERING HEAD 




EAS00676 

STEERING HEAD 



XhlONm(11.0m»kg) 



\ 


1st 


52 Nm (5.2 m-kg) 


2nd 


18Nm(1.8nvkg) 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the steering head 

Front wheel 




Remove the parts in the order listed. 
Refer to "FRONT WHEEL" 




Front fork 




Refer to "FRONT FORK" 




Handlebar 




Refer to "HANDLEBAR" 


1 


Front brake hose bracket 






2 


Horn /bracket 


1/1 




3 
4 
5 
6 


Brake hose joint 
Upper bracket cap nut 
Upper bracket 
Lock washer 






7 
8 


Upper ring nut 
Rubber washer 






9 


Lower ring nut 






10 


Dust cover 






11 
12 


Steering bearing (upper) 
Lower bracket 






13 


Steering bearing (lower) 




For installation, reverse the removal 
procedure. 



4-58 



STEERING HEAD 




REMOVING THE LOWER BRACKET 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 




2. Remove: 
•lower ring nut® 
(with the special tool (2)) 



v- 



Ring nut wrench 
90890-01403 



A WARNING 



Securely support the lower bracket so that 
there is no danger of it falling. 



CHECKING THE STEERING HEAD 

1. Wash: 
•bearings 
•bearing races 



*Y> 



Recommended cleaning solvent 
Kerosine 




2. Check: 
•bearings® 
•bearing races® 
Damage/pitting -+ Replace. 



3. Replace: 
•bearings 
•bearing races 



a. Remove the bearing races ® from the steer- 
ing head pipe with a long rod (2) and hammer. 



4-59 



STEERING HEAD 






b. Remove the bearing race (3) from the lower 
bracket with a floor chisel ® and hammer. 

c. Install a new rubber seal and new bearing 
races. 

CAUTION: 



If the bearing race is not installed properly, 
the steering head pipe could be damaged. 

NOTE: 

•Always replace the bearings and bearing 

races as a set. 
• Whenever the steering head is disassembled, 

replace the rubber seal. 

4. Check: 

•upper bracket 

• lower bracket 
(along with the steering stem) 
Bends/cracks/damage -► Replace. 

EAS00683 

INSTALLING THE STEERING HEAD 

1. Lubricate: 
•upper bearing 
•lower bearing 
•bearing races 



Recommended lubricant 
Lithium soap base grease 



2. Install: 

•lower ring nut® 
•rubber washer© 
•upper ring nut® 
• lock washer (4) 

Refer to "INSPECTING THE STEERING 

HEAD" in chapter 3. 

3. Install: 
•upper bracket 
•steering stem nut 

NOTE: 

Temporarily tighten the steering stem nut. 

4. Install: 
•front fork legs 

Refer to "FRONT FORK". 

NOTE: 

Temporarily tighten the upper and lower bracket 
pinch bolts. 



4-60 



REAR SHOCK ABSORBER ASSEMBLY 




REAR SHOCK ABSORBER ASSEMBLY 



X] 40 Nm (4.0 rrvkgl 




"XI 40 Nm (4.0 rrvkgY 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the rear shock absorber 
assembly 

Rear wheel 




Remove the parts in the order listed. 
Refer to "REAR WHEEL" 


1 
2 
3 
4 


Side cover (left/right) 
Connecting arm 
Relay arm 
Rear shock absorber 


1/1 

1 
1 
1 


For installation, reverse the removal 
procedure. 



4-61 



REAR SHOCK ABSORBER ASSEMBLY 





EAS00687 

HANDLING THE REAR SHOCK ABSORBER 
AND GAS CYLINDER 



A WARNING 



This rear shock absorber and gas cylinder 
contain highly compressed nitrogen gas. 
Before handling the rear shock absorber or 
gas cylinder, read and make sure you under- 
stand the following information. The 
manufacturer cannot be held responsible 
for property damage or personal injury that 
may result from improper handling of the 
rear shock absorber and gas cylinder. 
•Do not tamper or attempt to open the rear 
shock absorber or gas cylinder. 

• Do not subject the rear shock absorber or 
gas cylinder to an open flame or any other 
source of high heat. High heat can cause an 
explosion due to excessive gas pressure. 

• Do not deform or damage the rear shock 
absorber or gas cylinder in any way. If the 
rear shock absorber, gas cylinder or both 
are damaged, damping performance will 
suffer. 



— ► — < 
I I 



DISPOSING OF A REAR SHOCK ABSORB- 
ER AND GAS CYLINDER 

a. Gas pressure must be released before dis- 
posing of a rear shock absorber and gas cyl- 
inder. To release the gas pressure, drill a 2 — 
3 mm hole through the gas cylinder at a point 
15 — 20 mm from its end as shown. 



A WARNING 



Wear eye protection to prevent eye damage 
from released gas or metal chips. 



4-62 



REAR SHOCK ABSORBER ASSEMBLY 




EAS00694 

REMOVING THE REAR SHOCK ABSORBER 
ASSEMBLY 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 



NOTE: 

Place the motorcycle on a suitable stand so that 
the rear wheel is elevated. 




2. Remove: 
•connecting arm bolt® 

• relay arm bolt (2) 

• rear shock absorber assembly lower bolt (3) 

NOTE: 

While removing the rear shock absorber as- 
sembly lower bolt, hold the swingarm so that it 
does not dropdown. 



3. Remove: 

• rear shock absorber assembly upper bolt ® 

• rear shock absorber assembly 

NOTE: 

Raise the swingarm and then remove the rear 
shock absorber assembly from between the 
swingarm and relay arm. 



4-63 



REAR SHOCK ABSORBER ASSEMBLY 





EAS00696 

CHECKING THE REAR SHOCK ABSORBER 
ASSEMBLY 

1. Check: 

• rear shock absorber rod 
Bends/damage -► Replace the rear shock 
absorber assembly. 

• rear shock absorber 

Gas leaks/oil leaks -► Replace the rear 
shock absorber assembly. 

•spring 
Damage/wear -► Replace the rear shock ab- 
sorber assembly. 

•bushings 
Damage/wear -► Replace. 

•dust seals 
Damage/wear -+ Replace. 

• bolts 
Bends/damage/wear -+ Replace. 



INSTALLING THE REAR SHOCK ABSORB- 
ER ASSEMBLY 

1. Lubricate: 
• spacers 
•bearings 



Recommended lubricant 

Molybdenum disulfide grease 



2. Install: 
• rear shock absorber assembly 



V 



Rear shock absorber assembly 
upper nut 

40 Nm (4.0 nrkg) 
Rear shock absorber assembly 
lower nut 

40 Nm (4.0 nrkg) 
Relay-arm-to-frame-nut 

40 Nm (4.0 nrkg) 



NOTE: 

•When installing the rear shock absorber as- 
sembly, lift up the swingarm. 

•Install the connecting arm front bolt from the 
right. 



4-64 



SWINGARM AND DRIVE CHAIN 




SWINGARM AND DRIVE CHAIN 



125 Nm (12.5 m«kg)| r't-J 





XI 23 Nm (2.3 nvkg) 



Order 


Job/ Part 


Q'ty 


Remarks 




Removing the swing arm and drive 
chain 




Remove the parts in the order listed. 




Rear wheel 




Refer to "REAR WHEEL" 




Rear shock absorber assembly 




Refer to "REAR SHOCK ABSORBER 
ASSEMBLY- 


1 


Rear brake caliper 


1 




2 


Brake hose holder 


2 




3 

4 


Side protector (left/right) 
Pivot shaft 


1/1 
1 


NOTE: 

Remove the side protector assembly. 
Do not remove the center cap. 




5 
6 


Swing arm 
Drive chain case 


1 
1 




7 
8 


Drive chain guard 
Dust cover 


1 
2 




9 


Oil seal 


2 





4-65 



SWINGARM AND DRIVE CHAIN 




125Nm(12.5nvkg)| /(N 





23 Nm (2.3 m*kg) 



Order 


Job/Part 


Q'ty 


Remarks 


10 


Bearing 


2 




11 


Spacer 






12 


Shoft pedal assembly 






13 


Drive sprocket cover 






14 


Drive chain guide 






15 


Drive sprocket 






16 


Drive chain 




For installation, reverse the removal 
procedure. 



4-66 



SWINGARM AND DRIVE CHAIN 




EAS00703 

REMOVING THE SWINGARM 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 










J 


0\ A* „ 







NOTE: 

Place the motorcycle on a suitable stand so that 
the rear wheel is elevated. 



2. Remove: 
•connecting arm bolt® 

• relay arm bolt (2) 

• rear shock absorber assembly lower bolt (3) 

NOTE: 

When removing the rear shock absorber as- 
sembly lower bolt, hold the swingarm so that it 
does not dropdown. 

3. Check: 
•swingarm side play [A] 
•swingarm vertical movement E] 

a. Check the tightening torque of the pivot shaft 
nut. 



X 



Pivot shaft nut 

125 Nm (12.5 nrrkg) 



b. Check the swingarm side play [A] by moving 
the swingarm from side to side. 

c. If the swingarm side play is out of specifica- 
tion, check the spacers, bearings, washers, 
and dust covers. 




Swingarm side play (at the end 
of the swingarm) 
1.0 mm 



Check the swingarm vertical movement \S\ 
by moving the swingarm up and down. 
If swingarm vertical movement is not smooth 
or if there is binding, check the spacers, 
bearings, washers, and dust covers. 



4-67 



SWINGARM AND DRIVE CHAIN 




EAS00704 

REMOVING THE DRIVE CHAIN 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 










c 

12010701 


f 









NOTE: 

Place the motorcycle on a suitable stand so that 
the rear wheel is elevated. 



2. Remove: 
•foot rest (left) 
•drive sprocket cover 
•drive chain guide® 
•drive sprocket (2) 



EAS00707 

CHECKING THE SWINGARM 

1. Check: 
•swingarm 
Bends/cracks/damage -► Replace. 



2. Check: 
• pivot shaft 
Roll the pivot shaft on a flat surface. 
Bends -+ Replace. 



A WARNING 



Do not attempt to straighten a bent pivot 
shaft. 

3. Wash: 
• pivot shaft 
•dust covers 
•spacer 
•washers 
•bearings 



*Q 



Recommended cleaning solvent 
Kerosine 



4-68 



SWINGARM AND DRIVE CHAIN 





4. Check: 
•dust covers® 
•spacer© 
•oil seals® 

Damage/wear - 
•bearings® 

Damage/pitting 



Replace. 
+ Replace. 



5. Check: 
•connecting arms® 

• relay arm ® 
Damage/wear -► Replace. 

•bearings® 
•oil seals® 
Damage/pitting -► Replace. 

• spacers ® 
Damage/scratches -+ Replace. 



® © ® ® ® ® ® ® ® ® © 



^^^w^^ ugnzn 



12510206 



CHECKING THE DRIVE CHAIN 

1. Measure: 
•ten-link section @ of the drive chain 
Out of specification -► Replace the drive 
chain. 




Ten-link drive chain section limit 
(maximum) 
150.1 mm 



NOTE: 

•While measuring the ten-link section, push 
down on the drive chain to increase its tension. 

• Measure the length between drive chain roller 
® and® as shown. 

• Perform this measurement at two or three dif- 
ferent places. 




2. Check: 
•drive chain 
Stiffness -► Clean and lubricate or replace. 



4-69 



SWINGARM AND DRIVE CHAIN 





(D 





3. Clean: 
•drive chain 



a. Wipe the drive chain with a clean cloth. 

b. Put the drive chain in kerosine and remove 
any remaining dirt. 

c. Remove the drive chain from the kerosine 
and completely dry it. 

CAUTION: 



This motorcycle has a drive chain with small 
rubber O-rings ® between the drive chain 
side plates. Never use high-pressure water 
or air, steam, gasoline, certain solvents 
(e.g., benzine), or a coarse brush to clean the 
drive chain. High-pressure methods could 
force dirt or water into the drive chain's in- 
ternals, and solvents will deteriorate the O- 
rings. A coarse brush can also damage the 
O-rings. Therefore, use only kerosine to 
clean the drive chain. 



Check: 

►O-rings® 
Damage -► Replace the drive chain. 

►drive chain rollers (2) 
Damage/wear -► Replace the drive chain. 

►drive chain side plates (3) 
Damage/wear -► Replace the drive chain. 
Cracks -► Replace the drive chain and make 
sure that the battery breather hose is proper- 
ly routed away from the drive chain and be- 
low the swingarm. 
Lubricate: 

►drive chain 



Recommended lubricant 

Engine oil or chain lubricant 
suitable for O-ring chains 



CD 

f J \ y 

1 1 \ 

\ \ \ J 

1 \. v y 


® 


I i 

12560103 



6. Check: 

•drive sprocket 

• rear wheel sprocket 
More than 1 /4 tooth® wear -► Replace the 
drive chain sprockets as a set. 
Bent teeth -► Replace the drive chain sprock- 
ets as a set. 

© Correct 

(T) Drive chain roller 

(2) Drive chain sprocket 



4-70 



SWINGARM AND DRIVE CHAIN 




EAS00713 

INSTALLING THE DRIVE CHAIN 

1. Lubricate: 
•drive chain 



Recommended lubricant 

Engine oil or chain lubricant 
suitable for O-ring chains 




2. Install: 
•drive chain® 
•drive sproc ket (2) 
•washer®) ISEfl 

• drive sprocket nut (4) |XI 85 Nm (8.5 m«kg) 
•drive chain guide® 

NOTE: 

While applying the rear brake, tighten the drive 
sprocket nut. 

3. Bend the lock washer tab @ along a flat side 
of the nut. 

EAS00711 

INSTALLING THE SWINGARM 

1. Lubricate: 
•bearings 

• spacers 
•dust covers 

• pivot shaft 



Recommended lubricant 

Molybdenum disulfide grease 



48 Nm (4.8 rrvkg) 



2. Install: 

• relay arm 
•left connecting arm 

• right connecting arm |XI 48 Nm (4.8 m«kg) 



4-71 



SWINGARM AND DRIVE CHAIN 





NOTE: 

Install the connecting arm front bolt® from the 
right. 

3. Install: 

• rear shock absorber assembly 

•rear wheel 
Refer to "INSTALLING THE REAR SHOCK 
ABSORBER ASSEMBLY" and "REAR 
WHEEL". 

4. Adjust: 

•drive chain slack 
Refer to "ADJUSTING THE DRIVE CHAIN 
SLACK" in chapter 3. 




Drive chain slack 
40 ~ 50 mm 



CAUTION: 



A drive chain that is too tight will overload the 
engine and other vital parts, and one that is 
too loose can skip and damage the swingarm 
or cause an accident. Therefore, keep the 
drive chain slack within the specified limits. 



4-72 




CHAPTER 5 
OVERHAULING THE ENGINE 

ENGINE 5-1 

DRIVE SPROCKET AND EXHAUST PIPE 5-1 

LEADS AND HOSES 5-2 

ENGINE 5-3 

INSTALLING THE ENGINE 5-4 

CAMSHAFT 5-5 

CYLINDER HEAD COVERS 5-5 

CAMSHAFTS 5-6 

REMOVING THE CAMSHAFTS 5-8 

CHECKING THE CAMSHAFTS 5-9 

CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, 

AND TIMING CHAIN GUIDES 5-11 

CHECKING THE TIMING CHAIN TENSIONER 5-11 

INSTALLING THE CAMSHAFTS 5-12 

CYLINDER HEAD 5-16 

REMOVING THE CYLINDER HEADS 5-17 

CHECKING THE CYLINDER HEADS 5-17 

INSTALLING THE CYLINDER HEAD 5-18 

VALVES AND VALVE SPRINGS 5-19 

REMOVING THE VALVES 5-21 

CHECKING THE VALVES AND VALVE GUIDES 5-22 

CHECKING THE VALVE SEATS 5-24 

CHECKING THE VALVE SPRINGS 5-26 

CHECKING THE VALVE LIFTERS 5-27 

INSTALLING THE VALVES 5-27 

GENERATOR 5-29 

REMOVING THE GENERATOR 5-30 

INSTATLLING THE GENERATOR 5-30 

PICKUP COIL 5-32 

REMOVING THE PLCKUP COIL ROTOR 5-34 

INSTALLING THE PICKUP COIL ROTOR 5-34 




CLUTCH 5-36 

CLUTCH COVER 5-36 

CLUTCH 5-38 

REMOVING THE CLUTCH 5-40 

CHECKING THE FRICTION PLATES 5-40 

CHECKING THE CLUTCH PLATES 5-42 

CHECKING THE CLUTCH SPRINGS 5-42 

CHECKING THE CLUTCH HOUSING 5-43 

CHECKING THE CLUTCH BOSS 5-43 

CHECKING THE PRESSURE PLATE 5-43 

CHECKING THE PULL LEVER AND PULL ROD 5-43 

CHECKING THE STARTER CLUTCH 5-44 

INSTALLING THE CLUTCH 5-45 

SHIFT SHAFT 5-48 

GENERATOR ROTOR COVER 5-48 

CHECKING THE SHIFT SHAFT 5-49 

CHECKING THE STOPPER LEVER 5-49 

INSTALLING THE SHIFT SHAFT 5-49 

OIL PAN AND OIL PUMP 5-50 

REMOVING THE OIL PAN 5-53 

CHECKING THE OIL PUMP 5-53 

CHECKING THE RELIEF VALVE 5-54 

CHECKING THE OIL DELIVERY PIPE 5-54 

CHECKING THE OIL STRAINER 5-54 

ASSEMBLING THE OIL PUMP 5-54 

INSTALLING THE OIL PUMP 5-55 

INSTALLING THE OIL STRAINER 5-55 

INSTALLING THE OIL PAN 5-56 

CRANKCASE 5-57 

CRANKCASE 5-57 

CONNECTING RODS AND PISTONS 5-59 

CRANKSHAFT 5-60 

DISASSEMBLING THE CRANKCASE 5-61 

REMOVING THE CONNECTING RODS AND PISTONS 5-62 

REMOVING THE CRANKSHAFT ASSEMBLY 5-63 

CHECKING THE CYLINDERS AND PISTONS 5-64 

CHECKING THE PISTON RINGS 5-65 

CHECKING THE PISTON PINS 5-66 

CHECKING THE CRANKSHAFT AND CONNECTING RODS .... 5-67 

CHECKING THE CRANKCASE 5-72 

CHECKING THE BEARINGS AND OIL SEALS 5-72 

CHECKING THE SPROCKETS AND CHAINS 5-73 

INSTALLING THE CRANKSHAFT 5-73 

INSTALLING THE CONNECTING ROD AND PISTON 5-74 

ASSEMBLING THE CRANKCASE 5-76 




TRANSMISSION 5-78 

TRANSMISSION, SHIFT DRUM ASSEMBLY AND 

SHIFT FORKS 5-78 

REMOVING THE TRANSMISSION 5-83 

CHECKING THE SHIFT FORKS 5-83 

CHECKING THE SHIFT DRUM ASSEMBLY 5-84 

CHECKING THE TRANSMISSION 5-84 

INSTALLING THE TRANSMISSION 5-85 



ENGINE 




OVERHAULING THE ENGINE 
ENGINE 

DRIVE SPROCKET AND EXHAUST PIPE 



XI 10Nm(1.0nrkg) 




20 Nm (2.0 nvkg) 



85 Nm (8.5 m»kg) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the drive sprocket and 




Remove the parts in the order listed. 




exhaust pipe 








Carburetor 




Refer to "CARBURETOR" in chapter 6. 




Plug code 








Ignition coil 
Radiator 




] Refer to "RADIATOR" in chapter 7. 




Water hose 








Air iduction system 




Refer to "AIR INDUCTION SYSTEM" in 
chapter 6. 


1 


Side cover (left) 






2 


Stator coil coupler/oil level switch 


1/1 




3 


Shit rod 






4 


Drive sprocket cover 






5 


Drive sprocket 






6 


Water outlet hose 






7 


Exhaust pipe 




For installation, reverse the removal 
procedure. 



5-1 



ENGINE 




EAS00189 

LEADS AND HOSES 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the leads and hoses 




Remove the parts in the order listed. 


1 


Cover 


1 




2 


Clutch cable 


1 




3 


Nuetral switch/speed sensor/pickup 
coil lead 


1/1/1 


Disconnect. 


4 


Water head pipe 


1 




5 


Coolant outlet hose 


1 


For installation, reverse the removal pro- 
cedure. 



5-2 



EAS00191 

ENGINE 



ENGINE 





XI 33 Nm (3.3 m«kg) 



Order 


Job/ Part 


Q'ty 


Remarks 


1 


Removing the engine 

Down tube 


1 


Remove the parts in the order listed. 


2 
3 


Engine mounting bolt (front) 
Engine bracket 


2 

1 




4 
5 
6 


Engine mounting bolt (rear upper) 
Engine mounting bolt (rear lower) 
Engine 


1 
1 
1 


For installation, reverse the removal 
procedure. 



5-3 



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\\ /® 


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c ^jk\ 


k@C 


1 


(D^^ 


|k\ Y^y 


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(5)^- 


7- — re$. \ 11 J 

6$ 









Q^ 


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/N4_ ^-<^ 








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/If ® 




11^ 




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^^S) 


l$r<= 


^jj^ 


IB 


® 



ENGINE 




INSTALLING THE ENGINE 

1. Install: 
•engine mount bolt® 
•engine mount bolt (2) 
•engine mount bolt® 
•engine bracket® 
•engine mount bolt® 
•down tube® 



NOTE: 

Do not fully tighten the bolts. 



2. Tighten the bolts in the following order. 



X 



% 



Engine mount bolt ® 

55 Nm (5,5 m»kg) 
Engine mount bolt ® 

55 Nm (5.5 m»kg) 
Engine mount bolt ® 

33 Nm (3.3 nrkg) 
Engine mount bolt ® 

55 Nm (5.5 m»kg) 
Down tube ® 

24 Nm (2.4 nrkg) 



(v (3) f( 


})d*b[\ )/s\ 




nJI 





3. Install: 
•shift arm® 

NOTE: 



XI 10Nm(10m«kg) 



►Align the punch mark® in the shift shaft with 
the slot in the shift arm. 
►Align the bottom edge of the shift pedal with 
the mark on the frame-to-swingarm bracket. 



5-4 



EAS00194 

CAMSHAFT 

CYLINDER HEAD COVERS 



CAMSHAFT 




13Nm(1.3m«kg) 




3 IJEB 



Order 


Job/ Part 


Q'ty 


Remarks 




Removing the cylinder head cover 




Remove the parts in the order listed. 




Carburetor assembly 




Refer to "CARBURETORS" in chapter 6. 




Radiator assembly and thermostat 




Refer to "RADIATOR" and 




assembly 




"THERMOSTAT ASSEMBLY" in chapter 7. 


1 


Spark plug 


4 




2 


Cylinder head cover 


1 




3 


Cylinder head cover gasket 


1 




4 


Timing chain guide (top side) 


1 


For installation, reverse the removal 
procedure. 



5-5 



EAS00196 

CAMSHAFTS 



CAMSHAFT 




XI 10Nm(1.0nrkg) 



XI 10Nm(1.0nvkg) 



5 *(6) 




Order 



Job/ Part 



Q'ty 



Remarks 



1 
2 
3 
4 
5 
6 
7 
8 
9 
10 



Removing the camshafts 

Pickup coil rotor cover 

Float chamber air vent hose holder 

Timing chain tensioner 

Timing chain tensioner gasket 

Timing chain guide (exhaust side) 

Intake camshaft cap 

Dowel pin 

Exhaust camshaft cap 

Dowel pin 

Intake camshaft 

Exhaust camshaft 



Remove the parts in the order listed. 
Refer to "PICKUP COIL". 



1 
1 
1 
1 
3 
6 
3 
6 
1 
1 



~i NOTE: 



During removal, the dowel pins may still 
be connected to the camshaft caps. 



5-6 



CAMSHAFT 




XI 10Nm(1.0m«kg) 



XI 10Nm(1.0m«kg) 




Order 


Job/ Part 


Q'ty 


Remarks 


11 
12 
13 
14 


Intake camshaft sprocket 

Exhaust camshaft sprocket 

Pin 

Timing chain guide (intake side) 


1 
1 
1 
1 


For installation, reverse the removal 
procedure. 



5-7 




CAMSHAFT 




REMOVING THE CAMSHAFTS 

1. Remove: 

•pickup rotor coil cover 

2. Align: 

• "T" mark on the pickup coil rotor® 
(with the crankcase mating surface ©) 

a. Turn the crankshaft clockwise. 

b. When piston #1 is at TDC on the compres- 
sion stroke, align the "T" mark (a) with the 
crankcase mating surface®. 

NOTE: 

TDC on the compression stroke can be found 
when the camshaft lobes are turned away from 
each other. 




3. Loosen: 
•camshaft sprocket bolts ® 



4. Loosen: 
•cap bolt® 

5. Remove: 

•timing chain tensioner(2) 
• gasket 



6. Remove: 
• camshaft sprocket ® 

NOTE: 



To prevent the timing chain from falling into the 
crankcase, fasten it with a wire (2). 



5-8 




CAMSHAFT 




7. Remove 
•timing chain guide (exhaust side) ® 
•camshaft caps 
•dowel pins 

CAUTION: 



To prevent damage to the cylinder head, 
camshafts or camshaft caps, loosen the 
camshaft cap bolts in stages and in a criss- 
cross pattern, working from the outside in. 

8. Remove: 
•intake camshaft® 
• exhaust camshaft (2) 



CHECKING THE CAMSHAFTS 

1. Check: 
•camshaft lobes 
Blue discoloration/pitting/scratches 
place the camshaft. 



Re- 




2. Measure: 
• camshaft lobe dimensions (a) and © 
Out of specification -> Replace the cam- 
shaft. 




Camshaft lobe dimension limit 
Intake 
(D 32.4 mm 
© 24.85 mm 
Exhaust 
(a) 32.85 mm 
© 24.85 mm 



5-9 





CAMSHAFT 




3. Measure: 
•camshaft runout 
Out of specification 



Replace. 




Camshaft runout 
Less than 0.03 mm 



4. Measure: 
• camshaft-journal-to-camshaft-cap clear- 
ance 

Out of specification -* Measure the camshaft 
journal diameter. 




Camshaft-journal-to-camshaft- 
cap clearance 

0.028 ~ 0.062 mm 



a. Install the camshaft into the cylinder head 
(without the dowel pins and camshaft caps). 

b. Position a strip of Plastigauge® ® onto the 
camshaft journal as shown. 

c. Install the dowel pins and camshaft caps. 

NOTE: 

• Tighten the camshaft cap bolts in stages and in 
a crisscross pattern, working from the inner 
caps out. 

• Do not turn the camshaft when measuring the 
camshaft journal-to-camshaft cap clearance 
with the Plastigauge®. 




Camshaft cap bolt 
10Nm(1.0nrkg) 



d. Remove the camshaft caps and then mea- 
sure the width of the Plastigauge® ®. 



5. Measure: 
• camshaft journal diameter (a) 
Out of specification -+ Replace the cam- 
shaft. 

Within specification — ► Replace the cylinder 
head and the camshaft caps as a set. 




Camshaft journal diameter 
24.459 ~ 24.472 mm 



5-10 



CAMSHAFT 





CHECKING THE TIMING CHAIN, CAMSHAFT 
SPROCKETS, AND TIMING CHAIN GUIDES 

The following procedure applies to all of the 
camshaft sprockets and timing chain guides. 
1. Check: 
•timing chain® 
Damage/stiffness -+ Replace the timing 
chain and camshaft sprockets as a set. 



2. Check: 
•camshaft sprocket 

More than 1 /4 tooth® wear -► Replace the 
camshaft sprockets and the timing chain as a 
set. 

@ 1 1 A tooth 
(b) Correct 

® Timing chain roller 
(D Camshaft sprocket 

3. Check: 

•timing chain guide (exhaust side) ® 
•timing chain guide (intake side) (JD 
•timing chain guide (top side) (3) 

Damage/wear -► Replace the defective 

part(-s). 



CHECKING THE TIMING CHAIN TENSIONER 

1. Check: 
•timing chain tensioner 
Cracks/damage -► Replace. 



5-11 



CAMSHAFT 





2. Check: 
•one-way cam operation 
Rough movement — ► Replace the timing 
chain tensioner housing. 

a. Lightly press the timing chain tensioner rod 
into the timing chain tensioner housing by 
hand. 

NOTE: 

While pressing the timing chain tensioner rod, 
wind it clockwise with a thin screwdriver® until 
it stops. 

b. Remove the screwdriver and slowly release 
the timing chain tensioner rod. 

c. Make sure that the timing chain tensioner rod 
comes out of the timing chain tensioner 
housing smoothly. If there is rough move- 
ment, replace the timing chain tensioner. 



Check: 
»cap bolt 
■ copper washer 
■ spring 
■ gasket 
■ timing chain tensioner rod 

Damage/wear -► Replace the defective 

part(-s). 




EAS00217 

INSTALLING THE CAMSHAFTS 

1. Install: 
• exhaust camshaft ® 
•intake camshaft (2) 

NOTE: 



Install the camshafts with the punch mark @ 
facing up. 



2. Install: 
•dowel pins 
•intake camshaft caps 
•exhaust camshaft caps 

NOTE: 

Make sure that the punch marks ® on the cam- 
shafts are aligned with the arrow marks © on 
the camshaft caps. 
Out of alignment -► Reinstall. 



5-12 



CAMSHAFT 




3. Install: 
•camshaft cap bolts 

NOTE: 



XI 10Nm(1.0nvkg) 



Tighten the camshaft cap bolts in stages and in 
a crisscross pattern, working from the inner 
caps out. 



CAUTION: 



The camshaft cap bolts must be tightened 
evenly or damage to the cylinder head, cam- 
shaft caps, and camshafts will result. 




4. Install: 
•intake camshaft sprocket 
•exhaust camshaft sprocket 



c. 



Turn the crankshaft clockwise. 
When piston #1 is at TDC on the compres- 
sion stroke, align the "T" mark® on the pick- 
up coil rotor with the crankcase mating sur- 
face®. 

Place the timing chain onto both camshaft 
sprockets and then install the camshaft 
sprockets onto the camshafts. 

NOTE: 

When installing the camshaft sprockets, start 
with the exhaust camshaft and be sure to keep 
the timing chain as tight as possible on the ex- 
haust side. 



CAUTION: 



Do not turn the crankshaft when installing 
the camshaft to avoid damage or improper 
valve timing. 



5-13 




CAMSHAFT 




d. Turn both camshafts opposite each other so 
that the punch marks © in the camshaft are 
aligned with the arrow marks (8) in the cam- 
shaft caps as shown. 

e. While holding the camshafts, temporarily 
tighten the camshaft sprocket bolts. 



5. Install: 
•timing chain tensioner 



a. While lightly pressing the timing chain ten- 
sioner rod by hand, turn the tensioner rod ful- 
ly clockwise with a thin screwdriver®. 

b. With the timing chain tensioner rod turned all 
the way into the timing chain tensioner hous- 
ing (with the thin screwdriver still installed), 
install the gasket and the timing chain ten- 
sioner© onto the cylinder block. 



A WARNING 



Always use a new gasket. 



c. Tighten the timing chain tensioner bolts® to 
the specified torque. 



X 



Timing chain tensioner bolt 
10Nm(1.0nrkg) 



d. Remove the screwdriver, make sure that the 
timing chain tensioner rod releases, and then 
tighten the cap bolt to the specified torque. 



V 



Timing chain cap bolt 
12Nm(1.2iTTkg) 



6. Turn: 
•crankshaft 
(several turns clockwise) 



5-14 




CAMSHAFT 




7. Check: 
• 'T'mark® 
Make sure that the "T" mark® on the pickup 
coil rotor is aligned with the crankcase mat- 
ing surface®. 



►camshaft punch marks© 
Make sure that the marks © on the camshaft 
are aligned with the arrow marks ® in the 
comshaft caps. 
Out of alignment -► Adjust. 
Refer to the installation steps above. 



8. Measure: 
•valve clearance 

Out of specification -► Adjust. 
Refer to "ADJUSTING THE VALVE CLEAR- 
ANCE" in chapter 3. 

9. Install: 

•timing mark accessing screw 

XI 15Nm(15m«kg) 
•crankshaft end cover 



5-15 



CYLINDER HEAD 




CYLINDER HEAD 



1st 



2nd 



20 Nm (2.0 nvkg) 



50 Nm (5.0 rrvkg) 



12Nm(1.2m«kg) 




20 Nm (2.0 rrvkg) 



50 Nm (5.0 rrvkg) 



«D 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the cylinder head 




Remove the parts in the order listed. 




Engine 




Refer to "ENGINE". 




Intake and exhaust camshafts 




Refer to "CAMSHAFTS". 


1 


Cylinder head 


1 




2 


Cylinder head gasket 


1 




3 


Dowel pin 


2 


For installation, reverse the removal 
procedure. 



5-16 



CYLINDER HEAD 





o <5A^ ® 




o ^ y ^ Q 



ii a ,i il ii 

W U l' |i 1' 





REMOVING THE CYLINDER HEADS 

1. Remove: 
•cylinder head nuts 
•cylinder head cap nuts 
•cylinder head bolts 

NOTE: 



•Loosen the nuts in the proper sequence as 

shown. 
• Loosen each nut 1 12 of a turn at a time. After all 

of the nuts are fully loosened, remove them. 



CHECKING THE CYLINDER HEADS 

The following procedure applies to all of the cyl- 
inder heads. 

1. Eliminate: 
•carbon deposits 

(from the combustion chambers with a 
rounded scraper) 

NOTE: 

Do not use a sharp instrument to avoid damag- 
ing or scratching: 
•spark plug threads 
•valve seats 

2. Check: 
•cylinder head 

Damage/scratches -+ Replace, 
•cylinder head water jacket 
Mineral deposits/rust -+ Eliminate. 

3. Measure: 

•cylinder head warpage 
Out of specification -► Resurface the cylin- 
der head. 




Cylinder head warpage 
Less than 0.1 mm 



a. Place a straightedge ® and a thickness 
gauge (2) across the cylinder head. 

b. Measure the warpage. 

c. If the limited is exceeded, resurface the cylin- 
der head as follows. 

d. Place a 400 ~ 600 grit wet sandpaper on the 
surface plate and resurface the cylinder 
head using a figure-eight sanding pattern. 

NOTE: 

To ensure an even surface, rotate the cylinder 
head several times. 



5-17 




CYLINDER HEAD 




EAS00233 

INSTALLING THE CYLINDER HEAD 

1. Install: 
•gasket US |® 
•dowel pins (2) 

2. Install: 
•cylinder head 

NOTE: 



Pass the timing chain through the timing chain 
cavity. 




3. Tighten: 
•cylinder head nuts® - ® 

1st |XI 20 Nm (2.0 nvkg) 
2nd 



•cylinder head bolt®© 
NOTE: 



50 Nm (5.0 nrrkg) 



» First, tighten the nuts® ~ © to approximate- 
ly 20 Nm (2.0 m»kg) with a torque wrench. 
'Retighten the nuts to 50 Nm (5.0 m»kg). 



NOTE: 

•Apply engine oil onto the threads of the cylin- 
der head nuts. 

•Tighten the cylinder head nuts in the proper 
tightening sequence as shown and torque 
them in two stages. 

4. Install: 
•exhaust camshaft 
•intake camshaft 
Refer to "INSTALLING THE CAMSHAFTS". 



5-18 



VALVES AND VALVE SPRINGS 




VALVES AND VALVE SPRINGS 




Order 


Job/ Part 


Q'ty 


Remarks 




Removing the valves and valve 




Remove the parts in the order listed. 




springs 








Cylinder head 




Refer to "CYLINDER HEAD". 


1 


Intake valve lifter 


12 




2 


Intake valve pad 


12 




3 


Intake valve cotter 


24 




4 


Intake valve upper spring seat 


12 




5 


Intake valve spring 


12 




6 


Intake valve oil seal 


12 




7 


Intake valve lower spring seat 


12 




8 


Intake valve 


12 




9 


Intake valve guide 


12 





5-19 



VALVES AND VALVE SPRINGS 





Order 


Job/ Part 


Q'ty 


Remarks 


10 


Exhaust valve lifter 


8 




11 


Exhaust valve pad 


8 




12 


Exhaust valve cotter 


16 




13 


Exhaust valve upper spring seat 


8 




14 


Exhaust valve spring 


8 




15 


Exhaust valve oil seal 


8 




16 


Exhaust valve lower spring seat 


8 




17 


Exhaust valve 


8 




18 


Exhaust valve guide 


8 


For installation, reverse the removal 
procedure. 



5-20 



VALVES AND VALVE SPRINGS 




REMOVING THE VALVES 

The following procedure applies to all of the 
valves and related components. 

NOTE: 

Before removing the internal parts of the cylin- 
der head (e.g., valves, valve springs, valve 
seats), make sure that the valves properly seal. 








11171401 





1. Remove: 
•valve lifter® 
• valve pad (2) 

NOTE: 



Make a note of the position of each valve lifter 
and valve pad so that they can be reinstalled in 
their original place. 

2. Check: 
•valve sealing 
Leakage at the valve seat -► Check the valve 
face, valve seat, and valve seat width. 
Refer to "CHECKING THE VALVE SEATS". 

a. Pour a clean solvent ® into the intake and 
exhaust ports. 

b. Check that the valves properly seal. 

NOTE: 

There should be no leakage at the valve seat®. 



@L _^<//*^_^<^ 


z^Sy 


//r\\ 


KSIm 




U^ & /\ 


fc^llf/s 


'//^(2) 




— © 



3. Remove: 
•valve cotters® 

NOTE: 



Remove the valve cotters by compressing the 
valve spring with the valve spring compressor 
<D and attachment®. 



P 



Valve spring compressor 

90890-04019 
Valve spring compressor 
attachment 
Intake valve 

90890-04114 
Exhaust valve 
90890-04108 



5-21 



VALVES AND VALVE SPRINGS 





4. Remove: 
•upper spring seat® 
•valve spring (2) 
•oil seal® 
•lower spring seat® 
•valve® 

NOTE: 



Identify the position of each part very carefully 
so that it can be reinstalled in its original place. 



EAS00239 

CHECKING THE VALVES AND VALVE 
GUIDES 

The following procedure applies to all of the 
valves and valve guides. 
1. Measure: 
• valve-stem-to-valve-guide clearance 



Valve-stem-to-valve-guide clearance = 
Valve guide inside diameter [A] - 
Valve stem diameter \E\ 



Out of specification 
guide. 



Replace the valve 



7* 


Valve-stem-to-valve-guide 


'A 


clearance 




Intake 


0,010 ~ 0.037 mm 


<Limit>: 0.08 mm 


Exhaust 


0.020 ~ 0.047 mm 


<Limit>: 0.1 mm 



5-22 



VALVES AND VALVE SPRINGS 







11170601 



2. Replace: 
•valve guide 

NOTE: 



To ease valve guide removal and installation, 
and to maintain the correct fit, heat the cylinder 
head to 100°C in an oven. 



a. Remove the valve guide with a valve guide 
remover®. 

b. Install the new valve guide with a valve guide 
installer (2) and valve guide remover®. 

c. After installing the valve guide, bore the 
valve guide with a valve guide reamer® to 
obtain the proper valve-stem-to-valve-guide 
clearance. 



NOTE: 

After replacing the valve guide, reface the valve 
seat . 



P 



Valve guide remover 
Intake (4.0 mm) 

90890-04111 
Exhaust (4.5 mm) 

90890-04116 
Valve guide installer 
Intake (4.0 mm) 

90890-04112 
Exhaust (4.5 mm) 

90890-04117 
Valve guide reamer 
Intake 

90890-04113 
Exhaust 

90890-04118 



5-23 



VALVES AND VALVE SPRINGS 




3. Eliminate: 
•carbon deposits 

(from the valve face and valve seat) 

4. Check: 

• valve face 
Pitting/wear -+ Grind the valve face. 

•valve stem end 
Mushroom shape or diameter larger than the 
body of the valve stem -► Replace the valve. 




; 


V 




& 






Es- 






i 


//////////////////// 11172103 



5. Measure: 
•valve margin thickness @ 
Out of specification -► Replace the valve. 




Valve margin thickness 
0.5 ~ 0.9 mm 



6. Measure: 
•valve stem runout 
Out of specification 

NOTE: 



Replace the valve. 



•When installing a new valve, always replace 
the valve guide. 

• If the valve is removed or replaced, always re- 
place the oil seal. 




Valve stem runout 
0.01 mm 




CHECKING THE VALVE SEATS 

The following procedure applies to all of the 
valves and valve seats. 

1. Eliminate: 
•carbon deposits 

(from the valve face and valve seat) 

2. Check: 
•valve seat 

Pitting/wear -► Replace the cylinder head. 

3. Measure: 

•valve seat width® 

Out of specification -► Replace the cylinder 
head. 




Valve seat width 

Intake: 0.9 — 1.1 mm 
Exhaust: 0.9 ~ 1.1 mm 



5-24 



VALVES AND VALVE SPRINGS 





a. Apply Mechanic's blueing dye (Dykem) ® 
onto the valve face. 

b. Install the valve into the cylinder head. 

c. Press the valve through the valve guide and 
onto the valve seat to make a clear pattern. 

d. Measure the valve seat width. 

NOTE: 

Where the valve seat and valve face contacted 
one another, the blueing will have been re- 
moved. 



4. Lap: 
• valve face 
•valve seat 

NOTE: 



After replacing the cylinder head or replacing 
the valve and valve guide, the valve seat and 
valve face should be lapped. 





A 


D Jj 


* — ' 11171601 




5-25 



a. Apply a coarse lapping compound ® to the 
valve face. 

CAUTION: 

Do not let the lapping compound enter the 
gap between the valve stem and the valve 
guide. 

b. Apply molybdenum disulfide oil onto the 
valve stem. 

c. Install the valve into the cylinder head. 

d. Turn the valve until the valve face and valve 
seat are evenly polished, then clean off all of 
the lapping compound. 

NOTE: 

For the best lapping results, lightly tap the valve 
seat while rotating the valve back and forth be- 
tween your hand. 

e. Apply a fine lapping compound to the valve 
face and repeat the above steps. 

f. After every lapping procedure, be sure to 
clean off all of the lapping compound from 
the valve face and valve seat. 

g. Apply Mechanic's blueing dye (Dykem) onto 
the valve face. 

h. Install the valve into the cylinder head. 

i. Press the valve through the valve guide and 

onto the valve seat to make a clear impression, 
j. Measure the valve seat width (a) again. If the 

valve seat width is out of specification, reface 

and lap the valve seat. 



VALVES AND VALVE SPRINGS 



A^Jl 



is 




11171902 




EAS00241 

CHECKING THE VALVE SPRINGS 

The following procedure applies to all of the 
valve springs. 
1. Measure: 
•valve spring free length @ 

Out of specification -► Replace the valve 

spring. 




Valve spring free length 
Intake spring 

38.9 mm 
Exhaust spring 

40.67 mm 




2. Measure: 
•compressed spring force ® 
Out of specification -► Replace the valve 
spring. 

(b) Installed length 




Compressed spring force 
Intake 

8.2 - 9.6 kg at 34.5 mm 
Exhaust 

11.0 ~ 12.6 kg at 35.0 mm 





„ r^\ 
















w^bmmmm, ™ 



3. Measure: 
•valve spring tilt® 
Out of specification 
spring. 



Replace the valve 




Spring tilt limit 
Intake 

1.7 mm 
Exhaust 

1.8 mm 



5-26 



VALVES AND VALVE SPRINGS 





(T 


(2> 




X^% 








/* — 




*C M T 


(\ \ 












EAS00242 

CHECKING THE VALVE LIFTERS 

The following procedure applies to all of the 

valve lifters. 

1. Check: 
•valve lifter 
Damage/scratches -► Replace the valve lift- 
ers and cylinder head. 



INSTALLING THE VALVES 

The following procedure applies to all of the 
valves and related components. 
1. Deburr: 
•valve stem end 
(with an oil stone) 



Lubricate: 
►valve stem® 
►oil seal© 

(with the recommended lubricant) 



Recommended lubricant 
Molybdenum disulfide oil 



3. Install: 
•valve® 

•lower spring seat (2) 
•oil seal® 
•valve spring® 
•upper spring seat® 
(into the cylinder head) 

NOTE: 



Install the valve spring with the larger pitch @ 
facing up. 



(6) Smaller pitch 
NOTE: 



Make sure that each valve is installed in its origi- 
nal place. Refer to the following embossed 
marks. 

Right and left intake valve(-s): "4XV:" 
Middle intake valve(-s): "4XV." 
Exhaust valve(-s):"5LV" 



5-27 



VALVES AND VALVE SPRINGS 





4. Install: 
• valve cotters © 

NOTE: 

Install the valve cotters by compressing the 
valve spring with the valve spring compressor 
(D and attach merit®. 



p. 



Valve spring compressor 

90890-04019 
Attachment 
Intake valve 

90890-04114 
Exhaust valve 
90890-04108 



5. To secure the valve cotters onto the valve 
stem, lightly tap the valve tip with a soft-face 
hammer. 

CAUTION: 



Hitting the valve tip with excessive force 
could damage the valve. 

6. Install: 
• valve pad ® 
•valve lifter© 

NOTE: 

•Apply molybdenum disulfide oil onto the valve 
lifter and valve pad. 

•The valve lifter must move smoothly when ro- 
tated with a finger. 

•Each valve lifter and valve pad must be rein- 
stalled in its original position. 



5-28 



GENERATOR 




GENERATOR 



14Nm(1.4nvkg) 




i (6.5 nrlkg) + 60 c 



2 lJ13n 



XI 12Nm(1.2m»kg) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the stator coil assembly 




Remove the parts in the order listed. 




Rider seat and fuel tank 




Refer to "SEATS" and "FUEL TANK" in 
chapter 3. 




Bottom cowling 




Refer to "COWLINGS" in chapter 3. 




Engine oil 




Drain. 

Refer to "CHANGING THE ENGINE OIL" 

in chapter 3. 


1 


Generator rotor cover 






2 


Generator rotor cover gasket 






3 


Dowel pin 


2 




4 


Generator rotor bolt 






5 


Generator rotor 






6 


Stator coil assembly coupler 




Disconnect. 


7 


Stator coil assembly lead holder 






8 


Stator coil assembly 




For installation, reverse the removal 
procedure. 



5-29 








~~~Z^/ 


I o 


Ks 


ft 


ilk 

W 


\w 







GENERATOR 




REMOVING THE GENERATOR 

1. Remove: 
•generator rotor cover® 

NOTE: 



Loosen each bolt 1 /4 of a turn at a time, in 

stages and in a crisscross pattern. 

After all of the bolts are fully loosened, remove 

them. 



2. Remove: 
•generator rotor bolt® 
•washer 

NOTE: 

While holding the generator rotor (2) with the rotor 
holding tool (3), loosen the generator rotor bolt. 



p. 



Rotor holding tool 
90890-01235 



3. Remove: 
•generator rotor® 
(with the flywheel puller (2) and rotor holding 
tool (3)) 




Flywheel puller 
90890-01080 



INSTALLING THE GENERATOR 

1. Apply: 
•sealant 
(onto the stator coil assembly lead grommet) 



v- 



Yamaha bond No. 1215 
90890-85505 



2. Install: 
•generator rotor 
•washer 
•generator rotor bolt 



A WARNING 



Always use a new generator rotor bolt. 



CAUTION: 



• Clean the tapered portion of the crankshaft 
and the generator rotor hub with lacquer 
thinner. 

•Lubricate the generator rotor bolt threads 
with engine oil. 



5-30 




GENERATOR 




3. Tighten: 
•generator rotor bolt® 



65 Nm (6.5 nvkg) + 60° 



NOTE: 

•While holding the generator rotor (2) with the 
rotor holding tool (3), tighten the generator ro- 
tor bolt. 

•After tightening to 65 Nm (6.5 m»kg), tighten 
another 60°. 



y- 



Rotor holding tool 
90890-01235 



4. Install: 
• generator rotor cover 

NOTE: 



Tighten the generator rotor cover bolts in stages 
and in a crisscross pattern. 



5-31 



PICKUP COIL 




PICKUP COIL 



60 Nm (6.0 rrvkg) 





l^~10Nm(1.0m«kg) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the pickup coil and 
pickup coil rotor 

Rider seat and fuel tank 




Remove the parts in the order listed. 
Refer to "SEATS" and "FUEL TANK" in 




Bottom cowling and right side cowling 
Engine oil 




chapter 3. 

Refer to "COWLINGS" in chapter 3. 

Drain. 

Refer to "CHANGING THE ENGINE OIL" 




Generator rotor cover 




in chapter 3. 

Refer to "GENERATOR". 


1 
2 
3 
4 


Pickup coil lead holder 
Pickup coil rotor cover 
Pickup coil rotor cover gasket 
Dowel pin 


1 
1 
1 
2 





5-32 



PICKUP COIL 




XI 60 Nm (6.0 m«kg) 



IJ15BI 3 





1^10 Nm (1.0 m»kg) 



Order 


Job/ Part 


Q'ty 


Remarks 


5 
6 

7 


Pickup coil coupler 
Pickup coil 
Pickup coil rotor 


1 
1 
1 


Disconnect. 

For installation, reverse the removal 
procedure. 



5-33 



PICKUP COIL 





REMOVING THE PICKUP COIL ROTOR 

1. Remove: 

•pickup coil lead holder® 

• pickup coil rotor cover (2) 

NOTE: 

Loosen each bolt 1 /4 of a turn at a time, in 

stages and in a crisscross pattern. 

After all of the bolts are fully loosened, remove 

them. 

2. Remove: 

• pickup coil rotor bolt ® 
•washer 

•pickup coil rotor (2) 

NOTE: 

While holding the generator rotor® with the ro- 
tor holding tool (4), loosen the pickup coil rotor 
bolt. 



p. 



Rotor holding tool 
90890-01235 



INSTALLING THE PICKUP COIL ROTOR 

1. Install: 
•pickup coil rotor® 
•washer 
•pickup coil rotor bolt 

NOTE: 

When installing the pickup coil rotor, align the 
pin (2) in the crankshaft sprocket with the groove 
(a) in the pickup coil rotor. 



5-34 




PICKUP COIL 




2. Tighten: 
• pickup coil rotor bolt © 



60 Nm (6.0 nvkg) 



NOTE: 

While holding the generator rotor (2) with the ro- 
tor holding tool (3), tighten the pickup coil rotor 
bolt. 



p. 



Rotor holding tool 
90890-01235 



3. Apply: 
•sealant 
(onto the pickup coil lead grommet) 



v- 



Yamaha bond No. 1215 
90890-85505 



4. Install: 
•pickup coil rotor cover 
•pickup coil lead holder 

NOTE: 



•When installing the pickup coil rotor cover, 
align the timing chain guide (intake side) pin ® 
with the hole (2) in the pickup coil rotor cover. 

•Tighten the pickup coil rotor cover bolts in 
stages and in a crisscross pattern. 



5-35 



CLUTCH 




CLUTCH 

CLUTCH COVER 




12Nm(1.2nvkg) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the clutch cover 




Remove the parts in the order listed. 




Engine oil 




Drain. 

Refer to "CHANGING THE ENGINE OIL" 

in chapter 3. 


1 


Clutch cable 


1 




2 


Clutch cover 


1 




3 


Clutch cover gasket 


1 




4 


Dowel pin 


2 


For installation, reverse the removal 
procedure. 



5-36 



CLUTCH 





Order 


Job/ Part 


Q'ty 


Remarks 


1 
2 


Removing the pull lever shaft 

Circlip 
Pull lever 


2 

1 


Remove the parts in the order listed. 


3 

4 


Pull lever spring 
Pull lever shaft 


1 
1 




5 


Oil seal 


1 




6 


Bearing 


2 


For installation, reverse the removal 
procedure. 



5-37 



CLUTCH 




CLUTCH 




XI 70 Nm (7.0 nrkg) 



8 Nm (0.8 nvkg) 



Order 


Job/ Part 


Q'ty 


Remarks 




Removing the clutch 




Remove the parts in the order listed. 


1 


Clutch cover 


1 




2 


Pull rod 


1 




3 


Friction plate 


1 - 




4 


Clutch plate 


2 


Select. 


5 


Friction plate 


4 


Color code: Black 


6 


Clutch plate 


6 




7 


Friction plate 


3 


Color code: Blue 


8 


Friction plate 


1 


Refer to "INSTALLING THE CLUTCH". 


9 


Clutch damper spring 


1 




10 


Clutch damper spring seat 


1 - 





5-38 



CLUTCH 





8 Nm (0.8 nvkg) 



Order 


Job/Part 


Q'ty 


Remarks 


11 


Clutch boss nut 






12 


Lock washer 






13 


Clutch boss 






14 


Thrust washer 






15 


Clutch housing 






16 


Bearing 






17 


Starter clutch gear 






18 


Bearing 






19 


Starter clutch assembly 






20 


Circlip 






21 


Starter clutch idle gear 




For installation, reverse the removal 
procedure. 



5-39 




CLUTCH 




REMOVING THE CLUTCH 

1 . Straighten the lock washer tab. 

2. Loosen: 
•clutch boss nut® 

NOTE: 



While holding the clutch boss© with the univer- 
sal clutch holder®, loosen the clutch boss nut. 



y- 



Universal clutch holder 
90890-04086 




3. Remove: 
•clutch boss nut® 
• lock washer (2) 
•clutch boss® 



CHECKING THE FRICTION PLATES 

The following procedure applies to all of the fric- 
tion plates. 
1. Check: 
•friction plate 

Damage/wear -+ Replace the friction plates 

as a set. 



5-40 



j***~ ^y 




11411101 




CLUTCH 




2. Measure: 
•friction plate thickness 
Out of specification -► Replace the friction 
plates as a set. 

NOTE: 

Measure the friction plate at four places. 




Friction plate thickness 
Friction plate ® 
3.42 ~ 3.58 mm 
<Limit>: 3.32 mm 
Friction plate © 
2.92 - 3.08 mm 
<Limit>: 2.82 mm 





3. Measure: 
•assembly width® 
Out of specification 



Adjust. 




Assembly width 
43.1 ~ 43.9 mm 



a. Assembly width adjusted by clutch plate ® 
and®. 

b. Select the clutch plate from the following 
table. 

Clutch plate ® 



Part No. 


Thickness 




168-16325-00 


1.6 mm 




31 A-1 6325-00 


2.0 mm 


STD 


168-16324-00 


2.3 mm 




Clutch plate (2) 


Part No. 


Thickness 




31 A-1 6325-00 


2.0 mm 


STD 


168-16324-00 


2.3 mm 




NOTE: 



When adjusting the clutch assembly width [by 
replacing the clutch plate(s)], be sure to replace 
the clutch plate ® first. After replacing the 
clutch plate ® , if specifications cannot be met, 
replace the clutch plate (2). 



5-41 




CLUTCH 




EAS00281 

CHECKING THE CLUTCH PLATES 

The following procedure applies to all of the 
clutch plates. 
1. Check: 
•clutch plate 

Damage -► Replace the clutch plates as a 

set. 



2. Measure: 
•clutch plate warpage 
(with a surface plate and thickness gauge®) 
Out of specification -+ Replace the clutch 
plates as a set. 




Clutch plate warpage limit 
Less than 0.1 mm 



EAS00282 

CHECKING THE CLUTCH SPRINGS 

The following procedure applies to all of the 
clutch springs. 
1. Check: 
•clutch spring 

Damage -+ Replace the clutch springs as a 

set. 




2. Measure: 
•clutch spring free length 
Out of specification -► Replace the clutch 
springs as a set. 




Clutch spring free length 
50 mm 
<Limit>: 47.5 mm 



5-42 



CLUTCH 





CHECKING THE CLUTCH HOUSING 

1. Check: 
•clutch housing dogs 
Damage/pitting/wear -+ Deburr the clutch 
housing dogs or replace the clutch housing. 

NOTE: 

Pitting on the clutch housing dogs will cause er- 
ratic clutch operation. 



2. Check: 
•bearing 
Damage/wear 
ing. 



Replace the clutch hous- 



CHECKING THE CLUTCH BOSS 

1. Check: 
•clutch boss splines 
Damage/pitting/wear -► Replace the clutch 
boss. 

NOTE: 

Pitting on the clutch boss splines will cause er- 
ratic clutch operation. 



CHECKING THE PRESSURE PLATE 

1. Check: 
•pressure plate® 

Cracks/damage -► Replace, 
•bearing© 

Damage/wear -► Replace. 



CHECKING THE PULL LEVER AND PULL 
ROD 

1. Check: 
•pull lever® 
•pull rod© 

Damage/wear -► Replace the pull rod and 

pull lever pinion gear as a set. 



5-43 




CLUTCH 




2. Check: 
•pull rod bearing 
Damage/wear - 



Replace. 



CHECKING THE STARTER CLUTCH 

1. Check: 
•starter clutch rollers 
Damage/wear -► Replace. 



Check: 

■ starter clutch idle gear 
■ starter clutch drive gear 
■ starter clutch gear 

Burrs/chips/roughness/wear 

the defective part(-s). 



Replace 



3. Check: 
•starter clutch gear's contacting surfaces 
Damage/pitting/wear -► Replace the starter 
clutch gear. 



5-44 




CLUTCH 




Check: 
►starter clutch operation 



a. Install the starter clutch drive gear ® onto 
the starter clutch (2) and hold the starter 
clutch. 

b. When turning the starter clutch drive gear 
clockwise [A] , the starter clutch and the start- 
er clutch drive gear should engage. 

If the starter clutch drive gear and starter 
clutch do not engage, the starter clutch is 
faulty and must be replaced. 

c. When turning the starter clutch drive gear 
counterclockwise [H, it should turn freely. 

If the starter clutch drive gear does not turn 
freely, the starter clutch is faulty and must be 
replaced. 




INSTALLING THE CLUTCH 

1. Install: 
•clutch housing 

NOTE: 



• Make sure that the slots (a) in the clutch hous- 
ing align with the tabs © on the oil/water pump 
assembly drive sprocket. 

•Make sure that the primary driven gear teeth 
and primary drive gear teeth mesh correctly. 

• Make sure that the starter clutch gear teeth and 
starter clutch idle gear teeth mesh correctly. 




2. Install: 
•lock washer |_ 
•clutch boss nut® 

NOTE: 



XI 90 Nm (9-0 m«kg)~ 



While holding the clutch boss (2) with the univer- 
sal clutch holder®, tighten the clutch boss nut. 




Universal clutch holder 
90890-04086 



5-45 



CLUTCH 




3. Bend the lock washer tab along a flat side of 
the nut. 

4. Lubricate: 
•friction plates 
•clutch plates 

(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



5. Install: 
•friction plates 
•clutch plates 

NOTE: 



First, install a friction plate and then alternate 
between a clutch plate and a friction plate. 




Install the clutch damper spring seat ©, 
clutch damper spring (2) and friction plate 
(smaller size)®. 

Install the clutch plate and friction plate at fol- 
lowing the illustrated. 
Friction plate®: Color code/Blue 
Friction plate®: Color code/Black 
Clutch plate®: 20 mm 
Clutch plate®: Select. Refer to "CHECKING 
THE FRICTION PLATE" 




Measure: 

►assembly width® 
Out of specification -► Adjust. 
Refer to "CHECKING THE 
PLATE". 



FRICTION 




Assembly width 
43.1 ~ 43.9 mm 



5-46 




CLUTCH 




7. Install: 
•pressure plate® 

NOTE: 



Align the punch mark ® in the pressure plate 
with the punch mark (a) in the clutch boss. 



8. Install: 
•clutch springs 
•clutch spring bolts 

NOTE: 



8 Nm (0.8 nrrkg) 



Tighten the clutch spring bolts in stages and in a 
crisscross pattern. 



9. Install: 
•pull lever 

NOTE: 



Align the punch mark® in the pull lever shaft 
with the mark® on the clutch cover. 



10. Install: 
•dowel pins 
• gasket IS1SM 
•clutch cover 

NOTE: 



12Nm(1.2m«kg) 



►When installing the clutch cover, push the pull 
lever and check that the punch mark @ on the 
pull lever aligns with the mark® on the clutch 
cover. Make sure that the pull rod groove © 
and pull lever shaft groove @ are engaged. 

►Tighten the clutch cover bolts in stages and in 
a crisscross pattern. 



5-47 



SHIFT SHAFT 




SHIFT SHAFT 

GENERATOR ROTOR COVER 




Order 


Job/ Part 


Q'ty 


Remarks 




Removing the shift shaft and stopper 




Remove the parts in the order listed. 




lever 








Drive sprocket cover 




Refer to "ENGINE". 


1 


Shift shaft cover 






2 


Shift shaft cover gasket 






3 


Dowel pin 


2 




4 


Shift shaft 






5 


Shift shaft spring 






6 


Spacer 






7 


Stopper lever spring 






8 


Stopper lever 






9 


Collar 






10 


Shift shaft spring stopper 




For installation, reverse the removal 
procedure. 



5-48 



SHIFT SHAFT 





EAS00328 

CHECKING THE SHIFT SHAFT 

1. Check: 
•shift shaft® 

Bends/damage/wear -+ Replace, 
•shift shaft spring® 

Damage/wear -► Replace. 



CHECKING THE STOPPER LEVER 

1. Check: 
•stopper lever® 
Bends/damage -► Replace. 
Roller turns roughly -► Replace the stopper 
lever. 



(D- 


l/^^l 




* 




M©% If 



INSTALLING THE SHIFT SHAFT 

1. Install: 
•shift shaft spring stopper® 



•stopper lever spring (2) 
•stopper lever® 

NOTE: 



22 Nm (2.2 m*kg) 



►Apply LOCTITE® to the threads of the shift 
shaft spring stopper. 

► Hook the ends of the stopper lever spring onto 
the stopper lever and the crankcase boss. 

► Mesh the stopper lever with the shift drum seg- 
ment assembly. 




2. Install: 
•shift shaft® 
•spacer 

NOTE: 



•Lubricate the oil seal lips with lithium soap 

base grease. 
• Install the end of the shift shaft spring onto the 

shift shaft spring stopper (2). 



5-49 



OIL PAN AND OIL PUMP 




OIL PAN AND OIL PUMP 




10Nm(1.0m«kg) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the oil pan and oil pump 

Engine oil 




Remove the parts in the order listed. 

Drain. 

Refer to "CHANGING THE ENGINE OIL" 




Coolant 




in chapter 3. 

Drain. 

Refer to "CHANGING THE COOLANT" in 


1 


Radiator assembly and water pump 

outlet pipe 

Exhaust pipe assembly 

Oil level switch connector 




chapter 3. 

Refer to "RADIATOR" and "OIL COOLER" 

in chapter 5. 

Refer to "ENGINE". 

Disconnect. 


2 


Oil level switch 






3 


Oil level switch lead holder 






4 
5 
6 


Oil pan 

Oil pan gasket 

Dowel pin 


2 





5-50 



OIL PAN AND OIL PUMP 





XI 10Nm(1.0m«kg) 



Order 


Job/Part 


Q'ty 


Remarks 


7 


Drain pipe 






8 


Oil strainer 






9 


Oil pipe 






10 


Oil delivery pipe 






11 


Oil/water pump assembly drive 
sprocket cover 






12 


Dowel pin 






13 


Oil/water pump assembly 






14 


Relief valve assembly 




For installation, reverse the removal pro- 
cedure. 



5-51 



OIL PAN AND OIL PUMP 





XI 15Nm(1.5m»kg) 



Order 


Job/ Part 


Q'ty 


Remarks 




Disassembling the oil pump 




Disassemble the parts in the order listed. 


© 


Oil/water pump assembly driven 
sprocket 


1 




(2) 


Washer 


1 




® 


Oil pump housing 


1 




(?) 


Bearing 


1 




© 


Pin 


2 




© 


Oil pump outer rotor 


1 




(7) 


Oil pump inner rotor 


1 




® 


Pin 


1 


For assembly, reverse the disassembly 
procedure. 



5-52 



OIL PAN AND OIL PUMP 






^//////V////////. 



11710404 



EAS00362 

REMOVING THE OIL PAN 

1. Remove: 
•oil level switch® 
•oil pan(2) 

•engine oil drain bolt® 
• gasket 
•dowel pins 

NOTE: 



Loosen each bolt 1 /4 of a turn at a time, in 
stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them. 



CHECKING THE OIL PUMP 

1. Check: 
•oil pump drive gear® 
•oil pump driven gear (2) 
•oil pump housing 
•oil pump housing cover 

Cracks/damage/wear - 
fective part(-s). 

2. Measure: 

• inner-rotor-to-outer-rotor-tip clearance @ 

• outer-rotor-to-oil-pump-housing clearance 

© 

•oil-pump-housing-to-inner-rotor-and-outer- 
rotor clearance © 



Replace the de- 



Out of specification 

® Inner rotor 

(2) Outer rotor 

(3) Oil pump housing 



Replace the oil pump. 




Inner-rotor-to-outer-rotor-tip 
clearance 

0.09 ~ 0.15 mm 

<Limit>: 0.23 mm 
Outer-rotor-to-oil-pump-housing 
clearance 

0.03 ~ 0.08 mm 

<Limit>: 0.15 mm 
Oil-pump-housing-to-inner-rotor- 
and-outer-rotor clearance 

0.06 ~ 0.11 mm 

<Limit>: 0.18 mm 



3. Check: 
•oil pump operation 
Unsmooth -► Repeat steps (1 ) and (2) or re- 
place the defective part(-s). 



5-53 



OIL PAN AND OIL PUMP 





CHECKING THE RELIEF VALVE 

1. Check: 
•relief valve body® 
•relief valve (2) 
•spring® 
•O-ring® 

Damage/wear 

part(-s). 



Replace the defective 



CHECKING THE OIL DELIVERY PIPE 

1. Check: 

• oil delivery pipe® 

•oil pipe© 
Damage -► Replace. 

Obstruction — ► Wash and blow out with com- 
pressed air. 



CHECKING THE OIL STRAINER 

1. Check: 
•oil strainer® 
Damage -► Replace. 
Contaminants — ► Clean with engine oil. 



ASSEMBLING THE OIL PUMP 

1. Lubricate: 
•inner rotor 
•outer rotor 
•oil pump shaft 
(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



5-54 



OIL PAN AND OIL PUMP 





2. Install: 
•pin© 

•inner rotor (2) 
• outer rotor (§) 
•oil pump housing® 



V 



\ 



Oil pump housing screw 
10Nm(1.0nfTkg) 



NOTE: 

When installing the inner rotor, align the pin © in 
the oil pump shaft with the groove @ on the in- 
ner rotor (2). 



3. Check: 
•oil pump operation 
Refer to "CHECKING THE OIL PUMP". 




EAS00376 

INSTALLING THE OIL PUMP 

1. Install: 

•Oil pump | XI 12Nm(1.2m»kg) 
NOTE: 

Install the oil/water pump drive chain© onto 
the oil/water pump driven sprocket(2). 



INSTALLING THE OIL STRAINER 

1. Install: 
• oil strainer housing © |XI iQNm(i.Om»kg) 



LOCTITE 4 



NOTE: 

The arrow © on the oil strainer housing must 
point towards the front of the engine. 



5-55 



OIL PAN AND OIL PUMP 





EAS00380 

INSTALLING THE OIL PAN 

1. Install: 

• dowel pins 

• gasket |~ 



•Oil pan (D X 10Nm(10nvkg) 


•Oil level switch® X 10Nm(10m*kg) 


•engine oil drain bolt® 


X 43 Nm (4.3 m-kg) 




A WARNING | 



Always use new copper washers. 



NOTE: 

•Tighten the oil pan bolts in stages and in a 
crisscross pattern. 

•Lubricate the oil level switch's O-ring with en- 
gine oil. 



5-56 



EAS00381 

CRANKCASE 

CRANKCASE 



CRANKCASE 




XI 10Nm(1.0nrkg) 



10Nm(1.0m»kg) 




Order 


Job/ Part 


Q'ty 


Remarks 




Removing the crankcase 




Remove the parts in the order listed. 




Engine 




Refer to "ENGINE". 




Cylinder head 




Refer to "CYLINDER HEAD". 




Pickup coil and pickup coil rotor 




Refer to "PICKUP COIL". 




Stator coil assembly 




Refer to "GENERATOR". 




Clutch housing and starter clutch idle 




Refer to "CLUTCH". 




gear 








Oil/water pump assembly 




Refer to "OIL PAN AND OIL PUMP". 


1 


Timing chain 


1 




2 


Crankshaft sprocket 


1 




3 


Pin 


1 




4 


Oil/water pump assembly drive chain 
guide 


1 




5 


Oil/water pump assembly drive chain 


1 





5-57 



CRANKCASE 




XI 10Nm(1.0m«kg) 



10Nm(1.0nvkg) 




Order 


Job/ Part 


Q'ty 


Remarks 


6 


Oil/water pump assembly drive 
sprocket 


1 




7 


Washer 


1 




8 


Plate 


1 




9 


Lower crankcase 


1 




10 


Dowel pin 


3 


For installation, reverse the removal 
procedure. 



5-58 



CRANKCASE 




CONNECTING RODS AND PISTONS 




Order 


Job/ Part 


Q'ty 


Remarks 




Removing the connecting rods and 




Remove the parts in the order listed. 




pistons 






1 


Connecting rod cap 


4 




2 


Big end lower bearing 


4 




3 


Piston pin clip 


8 




4 


Piston pin 


4 




5 


Piston 


4 




6 


Connecting rod 


4 




7 


Big end upper bearing 


4 




8 


Top ring 


4 




9 


2nd ring 


4 




10 


Oil ring 


4 


For installation, reverse the removal 
procedure. 



5-59 



CRANKCASE 




CRANKSHAFT 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the crankshaft assembly 




Remove the parts in the order listed. 




Crankcase 




Separate. 

Refer to "CRANKCASE". 




Connecting rod caps 




Refer to "CONNECTING RODS AND 
PISTONS". 


1 


Crankshaft 


1 




2 


Crankshaft journal lower bearing 


5 




3 


Crankshaft journal upper bearing 


5 


For installation, reverse the removal 
procedure. 



5-60 



CRANKCASE 





EAS00384 

DISASSEMBLING THE CRANKCASE 

1 . Place the engine upside down. 

2. Remove: 
•crankcase bolts 

NOTE: 

•Loosen each bolt 1/4 of a turn at a time, in 
stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them. 

•Loosen the bolts in decreasing numerical or- 
der (refer to the numbers in the illustration). 

•The numbers embossed on the crankcase in- 
dicate the crankcase tightening sequence. 



3. Remove: 
•lower crankcase 

CAUTION: 



Tap on one side of the crankcase with a soft- 
face hammer. Tap only on reinforced por- 
tions of the crankcase, not on the crankcase 
mating surfaces. Work slowly and carefully 
and make sure that the crankcase halves 
separate evenly. 



M9 x 125 mm bolts:® ~ © 
M8 x 125 mm bolts:® ~ @ 
M6 x 1 00 mm bolts: (Q) ~ © , ^ 

4. Remove: 
•dowel pins 
•O-ring 

5. Remove: 

•crankshaft journal lower bearing 
(from the lower crankcase) 

NOTE: 



Identify the position of each crankshaft journal 
lower bearing so that it can be reinstalled in its 
original place. 



5-61 




CRANKCASE 



ENG 



m 



EAS00393 

REMOVING THE CONNECTING RODS AND 
PISTONS 

The following procedure applies to all of the 
connecting rods and pistons. 
1. Remove: 

•connecting rod cap® 

•big end bearings 

NOTE: 

Identify the position of each big end bearing so 
that it can be reinstalled in its original place. 





UJ 11221001 



2. Remove: 
•piston pin clips® 
•piston pin© 
• piston (3) 

CAUTION: 



Do not use a hammer to drive the piston pin 
out. 



NOTE: 

• For reference during installation, put identifica- 
tion marks on the piston crown. 

• Before removing the piston pin, deburr the pis- 
ton pin clip's groove and the piston's pin bore 
area. If both areas are deburred and the piston 
pin is still difficult to remove, remove it with the 
piston pin puller®. 



p. 



Piston pin puller 
90890-01304 



5-62 



CRANKCASE 





3. Remove: 
•top ring 
•2nd ring 
•oil ring 

NOTE: 



When removing a piston ring, open the end gap 
with your fingers and lift the other side of the ring 
over the piston crown. 



REMOVING THE CRANKSHAFT ASSEMBLY 

1. Remove: 
•crankshaft assembly ® 
•crankshaft journal upper bearings 
(from the upper crankcase) 

NOTE: 

Identify the position of each crankshaft journal 
upper bearing so that it can be reinstalled in its 
original place. 



5-63 



CRANKCASE 












£25> 




x<C" Da J^"n 


QE§P 









CHECKING THE CYLINDERS AND PISTONS 

The following procedure applies to all of the cyl- 
inders and pistons. 

1. Check: 
•piston wall 
•cylinder wall 

Vertical scratches -► Rebore or replace the 
cylinder, and replace the piston and piston 
rings as a set. 

2. Measure: 
•piston-to-cylinder clearance 

a. Measure cylinder bore "C" with the cylinder 
bore gauge. 

NOTE: 

Measure cylinder bore "C" by taking side-to- 
side and front-to-back measurements of the cyl- 
inder. Then, find the average of the measure- 
ments. 



Cylinder bore "C" 


74.00 ~ 74.01 mm 


Wear limit 


74.06 mm 


Taper limit "T" 


0.05 mm 


Out of round "FT 


0.05 mm 



"C" 


= 


maximum of D-| 


~D 6 








HJJJ 


= 


maximum of D 1 
D 5 or D 6 


or D 2 


- maximum 


of 




"R" 


= 


maximum of D-| 
D 2 D 4 or D 6 


D 3 or 


D 5 - minimum 


of 



b. If out of specification, replace the cylinder, 
and the piston and piston rings as a set. 



5-64 




CRANKCASE 




c. Measure piston skirt diameter "P" with the 
micrometer. 

(a) 0.5 mm from the bottom edge of the piston. 




Piston size "P" 

73.955 ~ 73.970 mm 



d. If out of specification, replace the piston and 
piston rings as a set. 

e. Calculate the piston-to-cylinder clearance 
with the following formula. 



Piston-to-cylinder clearance = 
Cylinder bore "C" - 
Piston skirt diameter "P" 




Piston-to-cylinder clearance 
0.030 ~ 0.055 mm 
<Limit>: 0.12 mm 



f. If out of specification, replace the cylinder, 
and the piston and piston rings as a set. 




CHECKING THE PISTON RINGS 

1. Measure: 
•piston ring side clearance 
Out of specification -► Replace the piston 
and piston rings as a set. 

NOTE: 

Before measuring the piston ring side clear- 
ance, eliminate any carbon deposits from the 
piston ring grooves and piston rings. 




Piston ring side clearance 
Top ring 

0.030 ~ 0.065 mm 
2nd ring 
0.020 ~ 0.055 mm 



5-65 




CRANKCASE 




2. Install: 
•piston ring 
(into the cylinder) 

NOTE: 



Level the piston ring in the cylinder with the pis- 
ton crown as shown. 



(a) 5 mm 
3. Measure: 
•piston ring end gap 

Out of specification 

ring. 

NOTE: 



Replace the piston 



The oil ring expander spacer's end gap cannot 
be measured. If the oil ring rail's gap is exces- 
sive, replace all three piston rings. 




Piston ring end gap 
Top ring 

0.32 - 0.44 mm 
2nd ring 

0.43 ~ 0.58 mm 
Oil ring 

0.10 ~ 0.35 mm 



CHECKING THE PISTON PINS 

The following procedure applies to all of the pis- 
ton pins. 
1. Check: 
•piston pin 
Blue discoloration/grooves -► Replace the 
piston pin and then check the lubrication sys- 
tem. 



/\ 














r^rjl / 











2. Measure: 
•piston pin outside diameter 
Out of specification -► Replace the piston 
pin. 




Piston pin outside diameter 
16.991 ~ 17.000 mm 



5-66 







i C_\r — ty-E- 


Tjfy^S 


-^^ 


\r Y 



CRANKCASE 




3. Measure: 
•piston pin bore inside diameter 
Out of specification -^ Replace the piston. 




Piston pin bore inside diameter 
17.002 ~ 17.013 mm 



Calculate: 

•piston-pin-to-piston clearance 
Out of specification -+ Replace the piston pin 
and piston as a set. 



Piston-pin-to-piston clearance = 
Piston pin bore size - 
Piston pin outside diameter 

Piston-pin-to-piston clearance 
0.002 ~ 0.022 mm 
<Limit>: 0.072 mm 



▲ 






© 


© 





A 

11631006 



CHECKING THE CRANKSHAFT AND CON- 
NECTING RODS 

1. Measure: 
•crankshaft runout 

Out of specification -► Replace the crank- 
shaft. 




Crankshaft runout 
Less than 0.03 mm 



2. Check: 

•crankshaft journal surfaces 
•crankshaft pin surfaces 
•bearing surfaces 
Scratches/wear -► Replace the crankshaft. 

3. Measure: 
•crankshaft-journal-to-crankshaft-journal- 
bearing clearance 

Out of specification -+ Replace the crank- 
shaft journal bearings. 




Crankshaft-journal-to-crankshaft- 
journal-bearing clearance 
0.029 ~ 0.053 mm 



5-67 



CRANKCASE 




CAUTION: 



Do not interchange the crankshaft journal 
bearings. To obtain the correct crankshaft- 
journal-to-crankshaft-journal-bearing clear- 
ance and prevent engine damage, the crank- 
shaft journal bearings must be installed in 
their original positions. 

a. Clean the crankshaft journal bearings, 
crankshaft journals, and bearing portions of 
the crankcase. 

b. Place the upper crankcase upside down on a 
bench. 




c. Install the crankshaft journal upper bearings 
® and the crankshaft into the upper crank- 
case. 

NOTE: 

Align the projections® of the crankshaft journal 
upper bearings with the notches® in the crank- 
case. 



d. Put a piece of Plastigauge^ 
crankshaft journal. 

NOTE: 



(2) on each 



Do not put the Plastigauge® over the oil hole in 
the crankshaft journal. 



e. Install the crankshaft journal lower bearings 
® into the lower crankcase and assemble 
the crankcase halves. 



NOTE: 

• Align the projections @ of the crankshaft jour- 
nal lower bearings with the notches ® in the 
crankcase. 

• Do not move the crankshaft until the clearance 
measurement has been completed. 



5-68 



CRANKCASE 






n — ^ 


/ 
\ 

J2 

/ 


_l \j 


\ 
J3 


/ 

\l 




"A 


J4 


/ 




J5 ] 





f. Tighten the bolts to specification in the tight- 
ening sequence cast on the crankcase. 



V 



\ 



Crankcase bolt 

Bolt ® ~ ® 

1st: 15Nm(1.5irrkg) 
2nd:15Nm(1.5nrkg) + 
45 ~ 50° 

Bolt© ~@,© ~©,@), 



12Nm(1.2irrkg) 

Bolt©,@ 

14Nm(1.4irrkg) 
Bolt ©~® 

24 Nm (24 irrkg) 



NOTE: 

Lubricate the crankcase bolt threads with en- 
gine oil. 

g. Remove the lower crankcase and the crank- 
shaft journal lower bearings. 

h. Measure the compressed Plastigauge® 
width © on each crankshaft journal. 
If the clearance is out of specification, select 
replacement crankshaft journal bearings. 



4. Select: 
•crankshaft journal bearings (J1 

NOTE: 



J5) 



•The numbers [A] stamped into the crankshaft 
web and the numbers (T) stamped into the low- 
er crankcase are used to determine the re- 
placement crankshaft journal bearing sizes. 

•"J1 — J5" refer to the bearings shown in the 
crankshaft illustration. 

• If "J1 ~ J5" are the same, use the same size 
for all of the bearings. 



For example, if the crankcase "J-|" and crank- 
shaft web "J-i" numbers are "6" and "2" respec- 
tively, then the bearing size for "J-|" is: 



Bearing size for J1 : 
J1 (crankcase) - J-| (crankshaft web) -2 
6-2-2 = 2 (Pink/black) 



5-69 




CRANKCASE 



ENG 



m 



CRANKSHAFT JOURNAL BEARING 
COLOR CODE 


-1 


Pink/violet 





Pink/white 


1 


Pink/blue 


2 


Pink/black 


3 


Pink/brown 



5. Measure: 
• crankshaft-pin-to-big-end-bearing clear- 
ance 

Out of specification -► Replace the big end 
bearings. 




Crankshaft-pin-to-big-end-bearing 
clearance 

0.031 ~ 0.055 mm 



The following procedure applies to all of the 
connecting rods. 



CAUTION: 



Do not interchange the big end bearings and 
connecting rods. To obtain the correct 
crankshaft-pin-to-big-end-bearing clear- 
ance and prevent engine damage, the big 
end bearings must be installed in their origi- 
nal positions. 

a. Clean the big end bearings, crankshaft pins, 
and bearing portions of the connecting rods. 

b. Install the big end upper bearing into the con- 
necting rod and the big end lower bearing 
into the connecting rod cap. 




NOTE: 

Align the projections® on the big end bearings 
with the notches © in the connecting rod and 
connecting rod cap. 



5-70 



CRANKCASE 










^4^ 


vf" 




^^ 








I /^^^ 


^© 




\L^ 




11630601 






c. Put a piece of Plastigauge® ® on the crank- 
shaft pin. 

d. Assemble the connecting rod halves. 

NOTE: 

• Do not move the connecting rod or crankshaft 
until the clearance measurement has been 
completed. 

•Apply molybdenum disulfide grease onto the 
bolts, threads, and nut seats. 

• Make sure that the "Y" mark© on the connect- 
ing rod faces towards the left side of the crank- 
shaft. 

• Make sure that the characters (3) on both the 
connecting rod and connecting rod cap are 
aligned. 

e. Tighten the connecting rod nuts. 
CAUTION: 



• When tightening the connecting rod nuts, 
be sure to use an F-type torque wrench. 

• Without pausing, tighten the connecting 
rod nuts to the specified torque. Apply con- 
tinuous torque between 2.0 and 3.6 m«kg. 
Once you reach 2.0 nrkg, DO NOT STOP 
TIGHTENING until the specified torque is 
reached. If the tightening is interrupted be- 
tween 2.0 and 3.6 m«kg, loosen the con- 
necting rod nut to less than 2.0 m*kg and 
start again. 

Refer to "INSTALLING THE CONNECTING 
RODS". 



V 



Connecting rod nut 
36 Nm (3.6 nrkg) 



f. Remove the connecting rod and big end 
bearings. 

Refer to "REMOVING THE CONNECTING 
RODS". 

g. Measure the compressed Plastigauge® 
width on the crankshaft pin. 

If the clearance is out of specification, select 
replacement big end bearings. 



5-71 



CRANKCASE 






n — ^ 
P1 


/ 
\ 

/ 


P2 


\ 


/ 

\l 


P3 


J 




/ 


P4 


] 



6. Select: 
•big end bearings (P-| 

NOTE: 



P 4 ) 



•The numbers [A] stamped into the crankshaft 
web and the numbers © on the connecting 
rods are used to determine the replacement 
big end bearing sizes. 

• "P1 " — "P5" refer to the bearings shown in the 
crankshaft illustration. 




For example, if the connecting rod "Pi" and the 
crankshaft web "Pi " numbers are "4" and "1 " re- 
spectively, then the bearing size for "P-j" is: 



Bearing size for "P^': 
"Pi" (connecting rod) - "P-," 
(crankshaft) -2 = 
4-1-2 = 1 (Blue) 



BIG END BEARING COLOR CODE 


-1 


Violet 





White 


1 


Blue 


2 


Black 



CHECKING THE CRANKCASE 

1 . Thoroughly wash the crankcase halves in a 
mild solvent. 

2. Thoroughly clean all the gasket surfaces and 
crankcase mating surfaces. 

3. Check: 
•crankcase 

Cracks/damage -► Replace, 
•oil delivery passages 
Obstruction -► Blow out with compressed air. 

EAS00401 

CHECKING THE BEARINGS AND OIL 
SEALS 

1. Check: 
•bearings 

Clean and lubricate the bearings, then rotate 
the inner race with your finger. 
Rough movement — ► Replace. 

2. Check: 
•oil seals 

Damage/wear -► Replace. 



5-72 



CRANKCASE 





CHECKING THE SPROCKETS AND CHAINS 

1. Check: 

• crankshaft sprocket ® 

•oil/water pump assembly drive sprocket© 
Cracks/damage/wear -► Replace the de- 
fective part(-s). 



2. Check: 

•timing chain® 
Damage/stiffness -► Replace the timing 
chain and crankshaft sprocket as a set. 

•oil/water pump assembly drive chain© 
Damage/stiffness -► Replace the oil/water 
pump assembly drive chain and oil/water 
pump assembly drive sprocket as a set. 



INSTALLING THE CRANKSHAFT 

1. Install: 

•crankshaft journal upper bearings® 
(into the upper crankcase) 

NOTE: 

•Align the projections® on the crankshaft jour- 
nal upper bearings with the notches © in the 
crankcase. 

•Be sure to install each crankshaft journal up- 
per bearing in its original place. 

2. Install: 
•crankshaft 



5-73 




CRANKCASE 




INSTALLING THE CONNECTING ROD AND 
PISTON 

The following procedure applies to all of the 
connecting rods and pistons. 
1. Install: 

•top ring® 

•2nd ring® 

•upper oil ring rail (3) 

•oil ring expander® 

•lower oil ring rail® 

NOTE: 

Be sure to install the piston rings so that the 
manufacturer's marks or numbers® face up. 




® 


® 




LV® 


vy^ \3J 11221202 



2. Install: 

• piston ® 

(onto the respective connecting rod ®) 
•piston pin® 

• piston pin clip IBIS | ® 

NOTE: 

•Apply engine oil onto the piston pin. 

• Make sure that the "Y" mark® on the connect- 
ing rod faces left when the arrow mark ® on 
the piston is pointing up. Refer to the illustra- 
tion. 

•Reinstall each piston into its original cylinder 
(numbering order starting from the left: #1 to 
#4). 

3. Lubricate: 

• piston 
•piston rings 
•cylinder 

(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



4. Offset: 
•piston ring end gaps 

@ Top ring 

® Lower oil ring rail 

© Upper oil ring rail 

@ 2nd ring 

® Oil ring expander 



5-74 



CRANKCASE 




5. Lubricate: 
•crankshaft pins 
•big end bearings 

•connecting rod big end inner surface 
(with the recommended lubricant) 



Recommended lubricant 
Engine oil 




6. Install: 

•big end bearings 
•connecting rod assembly 

(into the cylinder and onto the crankshaft 

pin), 
•connecting rod cap 

(onto the connecting rod) 

NOTE: 

•Align the projections on the big end bearings 
with the notches in the connecting rods and 
connecting rod caps. 

• Be sure to reinstall each big end bearing in its 
original place. 

•While compressing the piston rings with one 
hand, install the connecting rod assembly into 
the cylinder with the other hand. 

•Make sure that the "Y" marks @ on the con- 
necting rods face towards the left side of the 
crankshaft. 

• Make sure that the characters © on both the 
connecting rod and connecting rod cap are 
aligned. 

7. Align: 
•bolt heads 

(with the connecting rod caps) 

8. Tighten: 
•connecting rod nuts 



XI 36 Nm (3.6 nvkg) 



CAUTION: 



• When tightening the connecting rod nuts, 
be sure to use an F-type torque wrench. 

• Without pausing, tighten the connecting 
rod nuts to the specified torque. Apply con- 
tinuous torque between 2.0 and 3.6 m«kg. 
Once you reach 2.0 irrkg DO NOT STOP 
TIGHTENING until the specified torque is 
reached. If the tightening is interrupted be- 
tween 2.0 and 3.6 m«kg, loosen the con- 
necting rod nut to less than 2.0 m*kg and 
start again. 



5-75 



CRANKCASE 




EAS00414 

ASSEMBLING THE CRANKCASE 

1. Lubricate: 
•crankshaft journal bearings 
(with the recommended lubricant) 



Recommended lubricant 
Engine oil 




2. Apply: 
•sealant 
(onto the crankcase mating surfaces) 



Yamaha bond No. 1215 
90890-85505 



NOTE: 

Do not allow any sealant to come into contact 
with the oil gallery or crankshaft journal bear- 
ings. Do not apply sealant to within 2-3 mm of 
the crankshaft journal bearings. 

3. Install: 
•dowel pin 




4. Install: 

•crankshaft journal lower bearings® 
(into the lower crankcase) 

NOTE: 

•Align the projections® on the crankshaft jour- 
nal lower bearings with the notches © in the 
crankcase. 

• Install each crankshaft journal lower bearing in 
its original place. 

5. Set the shift drum assembly and transmis- 
sion gears in the neutral position. 



5-76 



\ / \ 




1 '6-~~y*$F\( y^~ 


<0 




i _^-© 






D _^@ 




s^Q$ 








CRANKCASE 




6. Install: 
•upper crankcase® 
(onto the lower crankcase (2)) 

CAUTION: 



Before tightening the crankcase bolts, make 
sure that the transmission gears shift cor- 
rectly when the shift drum assembly is 
turned by hand. 

7. Install: 
•crankcase bolts 



NOTE: 

•Lubricate the bolt threads with engine oil. 

• Tighten the bolts in increasing numerical order. 

• Install washers on bolts ® ~ ®. 

M9 x 125 mm bolts:® ~ ® 
M8 x 125 mm bolts:® ~ @ 
M6 x 100 mm bolts:® ~ @),@) ~ @) 



X 



Crankcase bolt 

Bolt © ~ © 

1st:15Nm(1.5m»kg) 
2nd:15Nm(1.5nvkg) + 
45 ~ 50° 

Bolt© -©,© -©,<§>, 



12Nm(1.2m«kg) 
Bolt®,© 

14Nm(1.4nvkg) 
Bolt © ~ <@> 

24 Nm (24 nvkg) 



5-77 



TRANSMISSION 



TRANSMISSION 

TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS 




XI 12Nm(1.2m»kg) 




r^ 1 "" IXI 10 Nm C-0 m*kgT 



Order 


Job/ Part 


Q'ty 


Remarks 




Removing the transmission, shift 
drum assembly, and shift forks 

Crankcase 




Remove the parts in the order listed. 

Separate. 

Refer to "CRANKCASE". 


1 
2 
3 


Stopper lever 
Drive axle assembly 
Circlip 
Oil seal 


1 
1 
1 


Refer to "SHIFT SHAFT". 


4 
5 


Bearing 

Shift drum retainer 


1 
1 




6 

7 
8 


Shift fork guide bar 

Spring 

Shift fork "L" 


2 

4 
1 




9 


Shift fork "R" 


1 


For installation, reverse the removal 
procedure. 



5-78 



TRANSMISSION 





Order 


Job/ Part 


Q'ty 


Remarks 


© 

(D 


Disassembling the main axle 
assembly 

2nd pinion gear 
Toothed lock washer 


1 
1 


Disassembly the parts in the order listed. 


(3) 


Toothed lock washer retainer 


1 




@ 

(D 

(6) 


6th pinion gear 
Toothed spacer 
Toothed washer 


1 
1 
2 




(Z) 
® 

(D 


Circlip 

3rd/4th pinion gears 

5th pinion gear 

Collar 


2 

1 
1 
1 





5-79 



TRANSMISSION 





Order 


Job/ Part 


Q'ty 


Remarks 


©> 


Main axle/ 1st pinion gear 

Bearing 

Main axle bearing housing 


1 
1 
1 


For assembly, reverse the disassembly 
procedure. 



5-80 



TRANSMISSION 





Order 


Job/ Part 


Q'ty 


Remarks 




Disassembling the drive axle 




Disassembly the parts in the order listed. 




assembly 






© 


Washer 


1 




© 


1st wheel gear 


1 




® 


Spacer 


1 




® 


5th wheel gear 


1 




© 


Circlip 


3 




© 


Washer 


3 




CD 


3rd wheel gear 


1 




(§) 


Toothed spacer 


2 




® 


Toothed lock washer 


1 




© 


Toothed lock washer retainer 


1 





5-81 



TRANSMISSION 





Order 


Job/Part 


Q'ty 


Remarks 


@ 


4th wheel gear 






© 


6th wheel gear 






© 


2nd wheel gear 






© 


Spacer 






© 


Drive axle 






© 


Bearing 






© 


Spacer 




For assembly, reverse the disassembly 
procedure. 



5-82 



TRANSMISSION 








REMOVING THE TRANSMISSION 

1. Remove: 
•main axle assembly® 
(with the Torx® wrench T30) 

a. Insert two bolts (2) of the proper size, as 
shown in the illustration, into the main axle 
assembly bearing housing. 

b. Tighten the bolts until they contact the crank- 
case surface. 

c. Continue tightening the bolts until the main 
axle assembly comes free from the upper 
crankcase. 



CHECKING THE SHIFT FORKS 

The following procedure applies to all of the shift 
forks and related components. 
1. Check: 
• shift fork cam follower ® 
•shift fork pawl© 
Bends/damage/scoring/wear -► Replace 
the shift fork. 



2. Check: 
•shift fork guide bar 
Roll the shift fork guide bar on a flat surface. 
Bends -+ Replace. 



A WARNING 



Do not attempt to straighten a bent shift fork 
guide bar. 



Check: 

►shift fork movement 
(on the shift fork guide bar) 
Rough movement — ► Replace the shift forks 
and shift fork guide bar as a set. 



5-83 



TRANSMISSION 










X 


^D 












- 


- 
























7T 
















A 

116507 


01 





CHECKING THE SHIFT DRUM ASSEMBLY 

1. Check: 
•shift drum grooves 

Damage/scratches/wear -► Replace the 

shift drum. 
• shift drum segment ® 

Damage/wear -► Replace, 
•shift drum bearing (2) 

Damage/pitting -► Replace. 



CHECKING THE TRANSMISSION 

1. Measure: 
•main axle runout 
(with a centering device and dial gauge ®) 
Out of specification -► Replace the main 
axle. 




Main axle runout limit 
0.08 mm 



Measure: 
►drive axle runout 

(with a centering device and dial gauge ®) 
Out of specification -► Replace the drive 
axle. 




Drive axle runout limit 
0.08 mm 



Check: 
■transmission gears 

Blue discoloration/pitting/wear -► Replace 

the defective gear(-s). 
■ transmission gear dogs 

Cracks/damage/rounded edges -► Replace 

the defective gear(-s). 

Check: 
■ transmission gear engagement 

(each pinion gear to its respective wheel 

gear) 

Incorrect — ► Reassemble the transmission 

axle assemblies. 

Check: 
■ transmission gear movement 

Rough movement — ► Replace the defective 

part(-s). 

Check: 
»circlips 

Damage/bends/looseness -► Replace. 



5-84 



TRANSMISSION 




INSTALLING THE TRANSMISSION 

•main axle assembly 

•shift fork "C" 

•shift drum assembly 

•shift fork "R" 

•shift fork "L" 

•springs 

•shift fork guide bars 

•drive axle assembly 

NOTE: 



►Carefully position the shift forks so that they 
are installed correctly into the transmission 
gears. 

► Install shift fork "C" into the groove in the 3rd 
and 4th pinion gear on the main axle. 

►Install shift fork "L" into the groove in the 6th 
wheel gear and shift fork "R" into the groove in 
the 5th wheel gear on the drive axle. 

► Make sure that the drive axle bearing circlip is 
inserted into the grooves in the upper crank- 
case. 



2. Check: 
•transmission 
Rough movement — ► Repair. 

NOTE: 



Oil each gear, shaft, and bearing thoroughly. 



5-85 



COOL 


tt 



CHAPTER 6 
COOLING SYSTEM 

RADIATOR 6-1 

CHECKING THE RADIATOR 6-2 

INSTALLING THE RADIATOR 6-3 

THERMOSTAT 6-4 

CHECKING THE THERMOSTAT 6-6 

ASSEMBLING THE THERMOSTAT 6-6 

INSTALLING THE THERMOSTAT 6-7 

WATER PUMP 6-8 

DISASSEMBLING THE WATER PUMP 6-10 

CHECKING THE WATER PUMP 6-10 

ASSEMBLING THE WATER PUMP 6-11 



RADIATOR 



COOL 


tt 



COOLING SYSTEM 



RADIATOR 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the radiator 




Remove the parts in the order listed. 




Coolant 




Drain. 


1 


Water inlet hose 






2 


Carburetor hose 






3 


Oil cooler hose 






4 


Water outlet hose 






5 


Radiator 






6 


Fan motor 




For installation, reverse the removal 
procedure. 



6-1 




RADIATOR 



COOL 


tt 



EAS00455 

CHECKING THE RADIATOR 

1. Check: 
•radiator fins 
Obstruction -► Clean. 

Apply compressed air to the rear of the radia- 
tor. 
Damage -► Repair or replace. 

NOTE: 

Straighten any flattened fins with a thin, flat- 
head screwdriver. 



2. Check: 
•radiator hoses 
•radiator pipes 
Cracks/damage 



Replace. 



3. Measure: 
•radiator cap opening pressure 
Below the specified pressure -► Replace the 
radiator cap. 




Radiator cap opening pressure 
95 ~ 125 kPa 
(0.95 ~ 1.25 kg /cm 2 ) 




a. Install the radiator cap tester® and adapter 
(2) to the radiator cap (3). 



p. 



Radiator cap tester 
90890-01325 

Adapter 

90890-01352 



b. Apply the specified pressure for ten seconds 
and make sure that there is no drop in pres- 
sure. 

4. Check: 
•radiator fan 
Damage -► Replace. 
Malfunction — ► Check and repair. 
Refer to "COOLING SYSTEM" in chapter 8. 



6-2 



RADIATOR 



COOL 


tt 



INSTALLING THE RADIATOR 

1. Fill: 
•cooling system 
(with the specified amount of the recom- 
mended coolant) 

Refer to "CHANGING THE COOLANT" in 
chapter 3. 




2. Check: 
•cooling system 
Leaks -► Repair or replace any faulty part. 

a. Attach the radiator cap tester® to the radia- 
tor. 



v- 



Radiator cap tester: 
90890-01325 



b. Apply 100 kPa (1 .0 kg/cm 2 ) of pressure. 

c. Measure the indicated pressure with the 
gauge. 



6-3 



THERMOSTAT 



COOL 


tt 



THERMOSTAT 




Order 


Job/ Part 


Q'ty 


Remarks 




Removing the thermostat 




Remove the parts in the order listed. 




Front cowling 




Refer to "FRONT COWLING" in chapter 3. 


1 


Coolant reservoir hose 


1 




2 


Water inlet hose 


1 




3 


Water outlet hose 


1 




4 


Thermostat housing 


1 


For installation, reverse the removal 
procedure. 



6-4 



THERMOSTAT 



COOL 


tt 




Order 


Job/ Part 


Q'ty 


Remarks 




Disassembling the thermostat housing 




Disassemble the parts in the order listed. 


© 


Thermostat housing cover 


1 




® 


Thermostat/O-ring 


1/1 




® 


Thermostat housing 


1 




@ 


Thermo unit 


1 


For assembly, reverse the disassembly 
procedure. 



6-5 





-3) 



-n 



~j£^4L 



(3) 



-® 



&&& & & 




THERMOSTAT 



COOL 


tt 



EAS00462 

CHECKING THE THERMOSTAT 

1. Check: 
•thermostat 
Does not open at 71 - 85°C -► Replace. 

a. Suspend the thermostat in a container filled 
with water. 

b. Slowly heat the water. 

c. Place a thermometer in the water. 

d. While stirring the water, observe the ther- 
mometer's indicated temperature. 

Thermometer 

(2) Water 

(3) Thermostat 

(4) Container 
[A] Closes 
\E Opens 

NOTE: 

If the accuracy of the thermostat is in doubt, re- 
place it. A faulty thermostat could cause serious 
overheating or overcooling. 



2. Check: 
•thermostat housing cover® 
•thermostat housing (2) 
Cracks/damage -► Replace. 



EAS00464 

ASSEMBLING THE THERMOSTAT 

1. Install: 
•thermostat housing ® 
•thermo stat® 
•0-rinq |glSK!l 
•thermostat housing cover 

NOTE: 



Install the thermostat with its breather hole (a) 
facing up. 



6-6 



THERMOSTAT 



COOL 


tt 




2. Install: 
•thermo unit® 

CAUTION: 



15Nm(1.5m«kg) 



Use extreme care when handling the thermo 
unit. Replace any part that was dropped or 
subjected to a strong impact. 



INSTALLING THE THERMOSTAT 

1. Fill: 
•cooling system 

(with the specified amount of the recom- 
mended coolant) 

Refer to "CHANGING THE COOLANT" in 
chapter 3. 

2. Check: 
•cooling system 

Leaks -► Repair or replace any faulty part. 



6-7 



WATER PUMP 



COOL 


tt 



WATER PUMP 




XI 10Nm(1.0m»kg) 



Order 


Job/Part 


Q'ty 


Remarks 




Disassembling the water pump 




Disassemble the parts in the order listed. 

NOTE: 

• The water pump and oil pump are 
combined into one unit (oil/water pump 
assembly). 

• It is not necessary to remove the 
impeller shaft unless the coolant level 
is extremely low or coolant leaks from 




Oil/water pump assembly and oil 




the oil pan. 


Refer to "OIL PAN AND OIL PUMP" in 




pump rotor 




chapter 5. 





Water pump cover 


1 




® 


O-ring 


1 




(D 


Pin 


2 







Impeller shaft (along with the impeller) 


1 





6-8 



WATER PUMP 



COOL 


tt 




XI 10Nm(1.0m«kg) 



Order 


Job/ Part 


Q'ty 


Remarks 


(D 


Water pump seal 
Oil seal 
Bearing 


1 
1 
1 


For assembly, reverse the disassembly 
procedure. 



6-9 



WATER PUMP 



COOL 


tt 




EAS00470 

DISASSEMBLING THE WATER PUMP 

1. Remove: 
•water pump seal® 

NOTE: 

Tap out the water pump seal from the inside of 
the water pump housing. 

(2) Water pump housing 



2. Remove: 
•oil sesal® 
•bearing© 

NOTE: 

Tap out the bearing and oil seal from the outside 
of the water pump housing. 



(3) Water pump housing 



3. Remove: 
• rubber damper holder ® 
•rubber damper (2) 

(from the impeller, with a thin, flat-head 

screwdriver) 

NOTE: 

Do not scratch the impeller shaft. 



CHECKING THE WATER PUMP 

1. Check: 

•water pump housing cover® 

•water pump housing (2) 

•impeller® 

•rubber damper® 

• rubber damper holder (5) 

2. Check: 
•water pump seal 
•oil seal 

•water pump inlet pipe 

Crack/damage/wear -► Replace 
•bearing 

Roughness -+ Replace. 



6-10 




WATER PUMP 



COOL 


tt 



EAS00475 

ASSEMBLING THE WATER PUMP 

1. Install: ^^ 
•oil seal Eg |® 
(to the water pump housing (2)) 
NOTE: 



► Install the oil seal with a socket that matches its 
outside diameter. 

► Before installing the oil seal, apply tap water or 
coolant onto its outer surface. 



\IE 




rl^lHD 




@k 








wl — WJr~Q) 




^^A 






\Hrf 


J§) 




U 1t- 


14150501 



2. Install: 
•water pump seal 

CAUTION: 



® 



Never apply oil or grease onto the water 
pump seal surface. 



NOTE: 

•Install the water pump seal with the water 

pump seal installers. 
•Before installing the water pump seal, apply 

Yamaha bond No. 121 5 (2) to the water pump 

housing®. 



P 



Water pump seal installer® 

90890-04078 
Middle driven shaft bearing 
driver® 

90890-04058 
Yamaha bond No.1215 

90890-85505 



[A] Push down 



6-11 




WATER PUMP 



COOL 


tt 



3. Install: ^^ 

• rubber damper ISBS | 

• rubber damper holder 

NOTE: 



Before installing the rubber damper, apply tap 
water or coolant onto its outer surface. 







5 


9 


V 14150203 



4. Measure: 
•tilt 

Out of specification 
(4). 

CAUTION: 



Repeat steps (3) and 



Make sure that the rubber damper and rub- 
ber damper holder are flush with the impel- 
ler. 




Tilt limit 
0.15 mm 



Straightedge 
(2) Impeller 



6-12 



CARB 


7 



CHAPTER 7 
CARBURETORS 

CARBURETORS 7-1 

AIR FILTER CASE 7-1 

CHECKING THE CARBURETORS 7-6 

ASSEMBLING THE CARBURETORS 7-8 

INSTALLING THE CARBURETORS 7-9 

MEASURING AND ADJUSTING THE FUEL LEVEL 7-10 

CHECKING AND ADJUSTING THE THROTTLE POSITION 

SENSOR 7-11 

CHECKING THE FUEL PUMP 7-13 

AIR INDUCTION SYSTEM 7-14 

AIR INJECTION 7-14 

AIR CUTOFF VALVE 7-14 

AIR INDUCTION SYSTEM DIAGRAMS 7-15 

CHECKING THE AIR INDUCTION SYSTEM 7-16 



CARBURETORS 



CARB 


7 



CARBURETORS 



CARBURETORS 

AIR FILTER CASE 




Order 


Job/ Part 


Q'ty 


Remarks 




Removing the air filter case 

Seat, fueltank and sidecovers 




Remove the parts in the order listed. 
Refer to "FRONT COWLING/SEAT/ 
SIDE COVER/FUEL TANK" section in 




Drain the coolant 




chapter 3. 

Refer to "CHANGING THE COOLANT" 

section. 


1 
2 
3 
4 
5 


Air filter case panel (left/right) 
Battery negative lead 
Battery positive lead 
Battery 
Stay 


1/1 
1 
1 
1 
1 


For installation, reverse the removal 
procedure. 



7-1 



CARBURETORS 



CARB 


7 




Order 


Job/ Part 


Q'ty 


Remarks 


1 
2 
3 


Removing the carburetors 

Throttle position sensor lead 
Air filter joint screw 
Carburetors joint screw 
Carburetor inlet/outlet hose 


4 

4 

1/1 


Remove the parts in the order listed. 
Disconnect. 


4 
5 


Carburetors assembly 
Starter cable 


1 
1 




6 


Throttle cable 


2 


For installation, reverse the removal 
procedure. 



7-2 



CARBURETORS 



CARB 


7 




Order 


Job/ Part 


Q'ty 


Remarks 




Separating the carburetor 




Remove the parts in the order listed. 


1 


Throttle stop screw 






2 


Coolant hose 






3 


Starter plunger link 






4 


Connecting bolt 






5 


Spacer 






6 


Connecting bolt 






7 


Spacer 


3 




8 


Fuel inlet pipe 


1 




9 


Fuel feed pipe 


2 




10 


Spring 


2 




11 


Vacuum chamber air vent hose 


2 




12 


Float chamber air vent hose 


2 




13 


Throttle position sensor 


1 




14 


Throttle position sensor bracket 


1 




15 


Carburetor 


4 


For installation, reverse the removal 
procedure. 



7-3 



CARBURETORS 



CARB 


7 




Order 


Job/Part 


Q'ty 


Remarks 




Disassembling the carburetor 




Disassemble the parts in the order listed. 

NOTE: 

The following procedure applies to all of 


® 


Starter plunger 




the carburetors. 




<D 


Pilot air jet 






(3) 


Vacuum chamber cover 






® 


Piston valve spring 






(5) 


Piston valve 






(6) 


Jet needle holder 






(7) 


Jet needle kit 






(8) 


Pilot screw 






(9) 


Fuel drain bolt 






© 


Float pin 







7-4 



CARBURETORS 



CARB 


7 




Order 


Job/ Part 


Q'ty 


Remarks 


(3D 


Float 






© 


Needle valve 






© 


Needle valve seat 






© 


Main jet 






© 


Main jet holder 






© 


Pilot jet 






© 


Needle jet 




For assembly, reverse the disassembly 
procedure. 



7-5 



CARBURETORS 



CARB 


7 



CHECKING THE CARBURETORS 

The following procedure applies to all of the car- 
buretors. 
1. Check: 

•carburetor body 

•float chamber 

•jet housing 
Cracks/damage -► Replace. 




2. Check: 
•fuel passages 
Obstruction -► Clean. 



Wash the carburetor in a petroleum-based 
solvent. Do not use any caustic-carburetor- 
cleaning solution. 

Blow out all of the passages and jets with 
compressed air. 



Check: 

►float chamber body® 
Dirt — ► Clean. 
Check: 

►float chamber rubber gasket© 
Cracks/damage/wear -+ Replace. 



5. Check: 
•float® 
Damage 



Replace. 



6. Check: 
•needle valve® 

• needle valve seat (2) 
Damage/obstruction/wear -► Replace the 
needle valve, needle valve seat and O-ring 
as a set. 

7. Check: 

• O-ring (3) 

Damage/wear -+ Replace the needle valve, 
needle valve seat and O-ring as a set. 



7-6 



CARBURETORS 



CARB 


7 




8. Check: 

• piston valve ® 
Damage/scratches/wear- 

• rubber diaphragm (2) 
Cracks/tears -► Replace. 



Replace. 



9. Check: 
•vacuum chamber cover® 
• piston valve spring (2) 
•jet needle holder® 
Cracks/damage -► Replace. 



10. Check: 

•jet needle kit® 

• needle jet (2) 
•main jet (3) 
•main jet holder® 

• pilot jet (5) 
•pilot screw® 

Bends/damage/wear -► Replace. 

Obstruction -► Clean. 

Blow out the jets with compressed air. 

11. Check: 

•piston valve movement 
Insert the piston valve into the carburetor 
body and move it up and down. 
Tightness -► Replace the piston valve. 

12. Check: 
•fuel feed pipes 
•hose joint 

Cracks/damage -► Replace. 

Obstruction -► Clean. 

Blow out the pipes with compressed air. 

13. Check: 

•fuel feed hoses 
•fuel hoses 

Cracks/damage/wear -► Replace. 

Obstruction -► Clean. 

Blow out the hoses with compressed air. 



7-7 



CARBURETORS 



CARB 


7 



EAS00489 

ASSEMBLING THE CARBURETORS 

The following procedure applies to both of the 
carburetors. 

CAUTION: 



•Before assembling the carburetors, wash 
all of the parts in a petroleum-based sol- 
vent. 

• Always use a new gasket. 










§- 




/£3"\ 


^X 




©Q 


3^ 


® 






\ ^_s=^ — ^J 1 \ 


i 






^Lf 








/ / l^^^VLP 14510502 



1. Install: 
•jet needle kit 



2. Install: 
•needle jet® 
•pilot jet <D 
•main jet (3) 



3. Measure: 
•float height® 
Out of specification 



Adjust. 




Float height 

12.5 ~ 13.5 mm 



a. Hold the carburetor upside down. 

b. Measure the distance from the mating sur- 
face of the float chamber (with the gasket re- 
moved) to the top of the float. 

NOTE: 

The float arm should rest on the needle valve 
without depressing it. 

c. If the float height is not within specification, 
check the needle valve seat and needle 
valve. 



7-8 



CARBURETORS 



CARB 


7 




d. If either the needle valve seat or needle valve 
is worn, replace them both. 

e. If both the needle valve seat and needle 
valve are fine, adjust the float height by bend- 
ing the float tang®. 

f. Check the float height again. 



4. Install: 
• piston valve 
•piston valve spring 
•vacuum chamber cover 

NOTE: 



Align the tab @ on the piston valve diaphragm 
with the recess © in the carburetor body. 



5. Install: 
•connecting bracket 

NOTE: 



After installing the connecting bracket, check 
that the throttle cable lever and starter plunger 
link operate smoothly. 



EAS00493 

INSTALLING THE CARBURETORS 

1. Adjust: 

•carburetor synchronization 
Refer to "SYNCHRONIZING THE CARBU- 
RETORS" in chapter 3. 

2. Adjust: 

•engine idling speed 



C\ 



Engine idling speed 
1,050 ~ 1,150 r/min 



Refer to "ADJUSTING THE ENGINE IDLING 
SPEED" in chapter 3. 



3. Adjust: 
•throttle cable free play 




Throttle cable free play (at the 
flange of the throttle grip) 
3-5 mm 



Refer to "ADJUSTING THE THROTTLE 
CABLE FREE PLAY" in chapter 3. 



7-9 




CARBURETORS 



CARB 


7 



MEASURING AND ADJUSTING THE FUEL 
LEVEL 

1. Measure: 
• fuel level® 
Out of specification -► Adjust. 




Fuel level (below the line on the 
float chamber) 
3.0 ~ 4.0 mm 



a. Stand the motorcycle on a level surface. 

b. Place the motorcycle on a suitable stand to 
ensure that the motorcycle is standing 
straight up. 

c. Install the fuel level gauge® to the fuel drain 
pipe®. 




Fuel level gauge 
90890-01312 



d. Loosen the fuel drain screw. 

e. Hold the fuel level gauge vertically next to the 
line on the float chamber (3). 

f . Measure the fuel level @ on both sides of the 
carburetor assembly. 

NOTE: 

The fuel level readings should be equal on both 
sides. 




2. Adjust: 
• fuel level 



a. Remove the carburetor assembly. 

b. Check the needle valve seat and needle 
valve. 

c. If either is worn, replace them as a set. 

d. If both are fine, adjust the float level by slight- 
ly bending the float tang ® . 

e. Install the carburetor assembly. 

f. Measure the fuel level again. 

g. Repeat steps (a) to (f) until the fuel level is 
within specification. 



7-10 



CARBURETORS 



CARB 


7 



CHECKING AND ADJUSTING 
THROTTLE POSITION SENSOR 

NOTE: 



THE 



(1) 


A 




1 


vY 


L / 


y/ 






















Sd 


V 


1 B/L ■ 



►Before adjusting the throttle position sensor, 
the engine idling speed should be properly ad- 
justed. 

►When installing the throttle position sensor, 
adjust its angle according to the RPM which is 
displayed on the tachometer. Refer to the ad- 
justment procedure below. 



1. Check: 
•throttle position sensor 



a. Disconnect the throttle position sensor cou- 
pler. 

b. Remove the throttle position sensor from the 
carburetor. 

c. Connect the pocket tester (ft x 1k) to the 
throttle position sensor. 



Tester positive lead -+ Black/blue® 
Tester negative lead -► Blue (2) 



d. Check the throttle position sensor maximum 
resistance. 

Out of specification -► Replace the throttle 
position sensor. 



at 



Throttle position sensor 
maximum resistance 
4 ~ 6kftat20°C 



e. Install the throttle position sensor onto the 
carburetor. 

f. Connect the pocket tester (Q x 1k) to the 
throttle position sensor. 



Tester positive lead -► Yellow Q 
Tester negative lead -► Blue (2) 



g. While slowly opening the throttle, check that 
the throttle position sensor resistance is with- 
in the specified range. 
Out of specification -► Replace the throttle 
position sensor. 



§4 



Throttle position sensor 
resistance 

0.4 ~ 5.4 kH at 20 °C 



7-11 



CARBURETORS 



CARB 


7 



2. Adjust: 
•throttle position sensor angle 




a. Turn the main switch to "ON". 

b. Disconnect the throttle position sensor cou- 
pler. 

c. Reconnect the throttle position sensor cou- 
pler. 

NOTE: 

After reconnecting the throttle position sensor 
coupler, the tachometer switches to the throttle 
position sensor adjustment mode. 

d. Loosen the throttle position sensor screws 

®. 

e. Adjust the throttle position sensor angle ac- 
cording to the following table: 

NOTE: 

The angle of the throttle position sensor is indi- 
cated by the RPM which are displayed on the 
tachometer. 



Tachometer reading 


Throttle position 
sensor angle 


r/min® 


Too small 


5,000 r/min (2) 


Correct 


10,000 r/min (3) 


Too large 



f. After adjusting the throttle position sensor 
angle, tighten the throttle position sensor 
screws. 

NOTE: 

To exit the throttle position sensor adjustment 
mode, start the engine or turn the main switch to 
"OFF". 



7-12 




CARBURETORS 



CARB 


7 



EAS00504 

CHECKING THE FUEL PUMP 

1. Check: 
•fuel pump® 

a. Place a container under the end of the fuel 
hose. 

b. Start the engine and check if fuel flows from 
the fuel hose®. 



Fuel flows. 


Fuel pump is OK. 


Fuel does not flow. 


Replace the fuel 
pump. 


c. Stop the engine and check if the fuel stops 
flowing from the fuel hose (2). 


Fuel stops flowing. 


Fuel pump is OK. 


Fuel flows. 


Replace the fuel 
pump. 



7-13 



AIR INDUCTION SYSTEM 



CARB 


7 



AIR INDUCTION SYSTEM 

AIR INJECTION 

The air induction system burns unburned ex- 
haust gases by injecting fresh air (secondary 
air) into the exhaust port, reducing the emission 
of hydrocarbons. 

When there is negative pressure at the exhaust 
port, the reed valve opens, allowing secondary 
air to flow into the exhaust port. The required 
temperature for burning the unburned exhaust 
gases is approximately 600 to 700°C. 




VIEW 1. (NO FLOW) 



^\U 




^\E 



AIR CUTOFF VALVE 

The air cutoff valve is operated by the intake gas 
pressure through the piston valve diaphragm. 
Normally, the air cutoff valve is open to allow 
fresh air to flow into the exhaust port. During 
sudden deceleration (the throttle valve sudden- 
ly closes), negative pressure is generated and 
the air cutoff valve is closed in order to prevent 
after-burning. 

Additionally, at high engine speeds and when 
the pressure decreases, the air cutoff valve au- 
tomatically closes to guard against a loss of per- 
formance due to self-EGR. 

VIEW 1. (NO FLOW) 

When decelerating (the throttle closes), the valve will 

close. 

VIEW 2. (FLOW) 

During normal operation the valve is open. 

[A] From the air cleaner 

\B\ To the reed valve 

[C| To the carburetor joint 



7-14 



AIR INDUCTION SYSTEM 



CARB 


7 



AIR INDUCTION SYSTEM DIAGRAMS 





Reed valve 

(2) Air cleaner 

(3) Air cutoff valve 

Carburetor joint (cylinder #4) 
[A] To the air cutoff valve 
El To cylinder #1 
[C| To cylinder #2 
[D] To cylinder #3 
[H To cylinder #4 



7-15 



AIR INDUCTION SYSTEM 



CARB 


7 



EAS00510 

CHECKING THE AIR INDUCTION SYSTEM 

1. Check: 
• hoses 

Loose connection -► Connect properly. 

Cracks/damage -► Replace, 
•pipes 

Cracks/damage -► Replace. 




2. Check: 
•fibre reed® 
•fibre reed stopper 
• reed valve seat 
Cracks/damage -► Replace the reed valve. 



3. Measure: 
•fibre reed bending limit® 
Out of specification -+ Replace the reed 
valve. 




Fibre reed bending limit 
0.2 mm 



® Surface plate 



4. Check: 
•air cutoff valve 
Cracks/damage -+ Replace. 



7-16 



ELEC 


+ 



CHAPTER 8 
ELECTRICAL 

ELECTRICAL COMPONENTS 8-1 

ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND 

COUPLERS 8-2 

INSTRUMENT FUENCTIONS 8-6 

CHECKING SWITCH CONTINUITY 8-8 

CHECKING THE SWITCHES 8-9 

CHECKING THE BULBS AND BULB SOCKETS 8-10 

TYPES OF BULBS 8-10 

CHECKING THE CONDITION OF THE BULBS 8-11 

CHECKING THE CONDITION OF THE BULB SOCKETS 8-12 

IGNITION SYSTEM 8-13 

CIRCUIT DIAGRAM 8-13 

TROUBLESHOOTING 8-14 

ELECTRIC STARTING SYSTEM 8-17 

CIRCUIT DIAGRAM 8-17 

STARTING CIRCUIT CUTOFF SYSTEM OPERATION 8-18 

TROUBLESHOOTING 8-19 

STARTER MOTOR 8-22 

CHECKING THE STARTER MOTOR 8-24 

ASSEMBLING THE STARTER MOTOR 8-25 

CHARGING SYSTEM 8-27 

CIRCUIT DIAGRAM 8-27 

TROUBLESHOOTING 8-28 

LIGHTING SYSTEM 8-30 

CIRCUIT DIAGRAM 8-30 

TROUBLESHOOTING 8-31 

SIGNAL SYSTEM 8-35 

CIRCUIT DIAGRAM 8-35 

TROUBLESHOOTING 8-37 

COOLING SYSTEM 8-43 

CIRCUIT DIAGRAM 8-43 

TROUBLESHOOTING 8-44 

FUEL PUMP SYSTEM 8-46 

CIRCUIT DIAGRAM 8-46 

FUEL PUMP CIRCUIT OPERATION 8-47 

TROUBLESHOOTING 8-48 

CHECKING THE FUEL PUMP 8-50 



ELEC 


+ 



EXUP SYSTEM 8-51 

CIRCUT DIAGRAM 8-51 

TROUBLESHOOTING 8-52 

SELF-DIAGNOSIS 8-55 

TROUBLESHOOTING 8-57 



ELECTRICAL COMPONENTS 



ELECTRICAL 



ELECTRICAL COMPONENTS 



© Main switch 
® Fuel sender 
© Rear brake switch 
@ Battery 
© Ignitor unit 
® Starter relay 



© Starting circuit cutoff relay 
® Flasher relay 
© Speed sensor 
© Sidestand switch 
© Neutral switch 



ELEC 


+ 



© Oil level gauge 

© Ignition coil 

© Rectifier/ Regulator 

©Thermo unit 

©Horn 

© Emargency stop switch 

@ Fan motor relay 




ARRANGEMENT OF THE ELECTRICAL 
COMPONENTS AND COUPLERS 



ELEC 


+ 



ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS 

©Thermo unit 

©T.P.S. 

(D Starter motor 

Pickup rotor 

(5) Pickup coil 




ARRANGEMENT OF THE ELECTRICAL 
COMPONENTS AND COUPLERS 



ELEC 


+ 



© Ignitor unit 

® Fuse box 

® Battery 

Fuel pump 

® Fuel pump coupler 

® Brake light switch coupler 

® Newtral switch coupler 

© Pickup coil coupler 

© Speed sensor coupler 




ARRANGEMENT OF THE ELECTRICAL 
COMPONENTS AND COUPLERS 



ELEC 


+ 



© Ignition coil #2.3 

(2) Ignition coil #1.4 

(3) Rectifier/regulator 
Stator coil 




ARRANGEMENT OF THE ELECTRICAL 
COMPONENTS AND COUPLERS 



ELEC 


+ 



© Emargency stop switch 

® Flasher relay 

© Starter relay 

© Fan motor relay 

® Starting circuit cutoff relay 

© Stator coil coupler 

© Sidestand switch coupler 

® Fuel sender coupler 

© Oil level switch coupler 




INSTRUMENT FUNCTIONS 



ELEC 


+ 



INSTRUMENT FUNCTIONS 

INDICATOR LIGHTS 




© Turn indicator light (left) " <? " 
© Turn indicator light (right) " " 
©Neutral indicator light "N " 
@ High beam indicator light " eO " 

WARNING LIGHT 



© Oil level warning light " <&* " 

@ Coolant temperature warning light " ± 

© Fuel level warning light "B " 



Turn indicator light "<?""<>" 

This indicator flashes when the turn switch is 
moved to the left or right, and the hazard 
switch is on. 

Neutral indicator light "N" 

This indicator comes on when the transmis- 
sion is in neutral. 

High beam indicator light "^O" 

This indicator comes on when the headlight 
high beam is used. 




Oil evel warning light "^" 

This warning light comes on when the engine 
oil level is low. If this symbol flashes, stop the 
engine immediately and fill it with oil to the 
specified level. 

Coolant temperature warning light "-£" 
This warning light comes on when the cool- 
ant temperature is too high. 

Fuel level warning light "*" 

When the fuel level drops below approxi- 
mately 5.5 L, this light will come on. When this 
light comes on, fill the fuel tank at the first op- 
portunity. 

CAUTION: 



• Do not run the motorcycle until you know it 

has sufficient engine oil. 
•Do not run the motorcycle if the engine is 

overheated. 



NOTE: 

Even if the oil is filled to the specified level, the 
warning light may flicker when riding on a slope 
or during sudden acceleration or deceleration, 
but this is normal. 



8-6 



INSTRUMENT FUNCTIONS 



ELEC 


+ 



DIGITAL CLOCK 




© "SELECT" button 
© "RESET" button 



Clock 

To set the clock: 

1 . Push both the "SELECT"© and "RESET"© 
buttons for at least two seconds. 

2. When the hour digits start flashing, push the 
"RESET" button © to set the hours. 

3. Push the "SELECT" button © to change the 
minutes. 

4. When the minute digits start flashing, push 
the "RESET" button © to set the minutes. 

5. Push the "SELECT" button © to start the 
clock. 

NOTE: 

After setting the clock, be sure to push the "SE- 
LECT" button © before turning the main switch 
to "OFF", otherwise the clock will not be set. 



8-7 



CHECKING SWITCH CONTINUITY 



ELEC 


+ 






® 






p 


O 






o 


o 












OFF 
















ON 


o 


o 


o 


o 


o 


o 


o 




















(6) { L/R L Br/L R Br/R L7Y B 
1 1 1 1 1 1 1 





CHECKING SWITCH CONTINUITY 

Check each switch for continuity with the pocket 
tester. If the continuity reading is incorrect, 
check the wiring connections and if necessary, 
replace the switch. 

CAUTION: 



Never insert the tester probes into the cou- 
pler terminal slots (T). Always insert the 
probes from the opposite end of the coupler, 
taking care not to loosen or damage the 
leads. 



p. 



Pocket tester 
90890-03112 



NOTE: 

•Before checking for continuity, set the pocket 
tester to "0" and to the "£l x 1 " range. 

• When checking for continuity, switch back and 
forth between the switch positions a few times. 

The terminal connections for switches (e.g., 
main switch, engine stop switch) are shown in 
an illustration similar to the one on the left. 
The switch positions® are shown in the far left 
column and the switch lead colors® are shown 
in the top row in the switch illustration. 

NOTE: 

"O O" indicates a continuity of electricity 

between switch terminals (i.e., a closed circuit 
at the respective switch position). 

The example illustration on the left shows 
that: 

There is continuity between blue/red and red 
when the switch is set to "P". 
There is continuity between blue/red and blue 
when the switch is set to "ON". 



8-8 



CHECKING THE SWITCHES 



ELEC 


+ 



CHECKING THE SWITCHES 

Check each switch for damage or wear, proper connections, and also for continuity between the termi 
nals. Refer to "CHECKING SWITCH CONTINUITY". 

Damage/wear -► Repair or replace the switch. 

Improperly connected -► Properly connect. 

Incorrect continuity reading -► Replace the switch. 







p 


o 








o 












OFF 
















ON 


o 


o 


o 


o 


o 


o 


o 



















OFF 








ON 


o 


o 




(D 




HI 


o 


o 




LO 








® 




OFF 








ON 


o 


o 






OFF 








ON 


o 


o 


o 


@ 


R 




o 


o 


N 








L 


o 


o 






Main switch 
@ Pass switch 
Dimmer switch 
Horn switch 
© Clutch switch 
Hazard switch 



0Turn signal switch 
Front brake switch 
Light switch 
Engine stop switch 
@ Start switch 



Rear brake switch 

0Fuse 

Side stand switch 

Neutral switch 

Oil level switch 



8-9 



CHECKING THE BULBS AND BULB SOCKETS 



ELEC 


+ 



CHECKING THE BULBS AND 

BULB SOCKETS 

Check each bulb and bulb socket for damage or 
wear, proper connections, and also for continu- 
ity between the terminals. 
Damage/wear -► Repair or replace the bulb, 
bulb socket or both. 

Improperly connected -+ Properly connect. 
Incorrect continuity reading -► Repair or replace 
the bulb, bulb socket or both. 




TYPES OF BULBS 

The bulbs used on this motorcycle are shown in 

the illustration on the left. 

•Bulbs (§) are used for headlights and usually 
use a bulb holder which must be detached be- 
fore removing the bulb. The majority of these 
bulbs can be removed from their respective 
socket by turning them counterclockwise. 

•Bulb (D is used for turn signal and tail/brake 
lights and can be removed from the socket by 
pushing and turning the bulb counterclock- 
wise. 

• Bulbs© are used for meter and indicator lights 
and can be removed from their respective 
socket by carefully pulling them out. 



8-10 



CHECKING THE BULBS AND BULB SOCKETS 



ELEC 


+ 



CHECKING THE CONDITION OF THE 
BULBS 

The following procedure applies to all of the 
bulbs. 

1. Remove: 
•bulb 



A WARNING 



Since the headlight bulb gets extremely hot, 
keep flammable products and your hands 
away from the bulb until it has cooled down. 



CAUTION: 



• Be sure to hold the socket firmly when re- 
moving the bulb. Never pull the lead, other- 
wise it may be pulled out of the terminal in 
the coupler. 

• Avoid touching the glass part of the head- 
light bulb to keep it free from oil, otherwise 
the transparency of the glass, the life of the 
bulb and the luminous flux will be adverse- 
ly affected. If the headlight bulb gets soiled, 
thoroughly clean it with a cloth moistened 
with alcohol or lacquer thinner. 

2. Check: 
•bult (for continuity) 
(with the pocket tester) 
No continuity -► Replace. 



v- 



Pocket tester 
90890-03112 



NOTE: 

Before checking for continuity, set the pocket 
tester to "0" and to the "£l x 1" range. 




a. Connect the tester positive probe to terminal 
© and the tester negative probe to terminal 
(2), and check the continuity. 

b. Connect the tester positive probe to terminal 
® and the tester negative probe to terminal 
(3), and check the continuity. 

c. If either of the readings indicate no continuity, 
replace the bulb. 



8-11 



CHECKING THE BULBS AND BULB SOCKETS 



ELEC 


+ 



CHECKING THE CONDITION OF THE BULB 
SOCKETS 

The following procedure applies to all of the bulb 
sockets. 
1. Check: 
•bulb socket (for continuity) 

(with the pocket tester) 

No continuity -► Replace. 



y- 



Pocket tester 
90890-03112 



NOTE: 

Check each bulb socket for continuity in the 
same manner as described in the bulb section; 
however, note the following. 



001 


T 




<* 




f } r 






_±J I- 













a. Install a good bulb into the bulb socket. 

b. Connect the pocket tester probes to the re- 
spective leads of the bulb socket. 

c. Check the bulb socket for continuity. 

If any of the readings indicate no continuity, 
replace the bulb socket. 

CHECKING THE LEDs 

The following procedures applies to all of the 
LEDs. 
1. Check: 
•LED (for proper operation) 
Improper operation -► Replace. 

a. Disconnect the meter assembly coupler (me- 
ter assembly side). 

b. Connect two jumper leads ® from the bat- 
tery terminals to the respective coupler ter- 
minal as shown. 



A WARNING 



• A wire that is used as a jumper lead must 
have at least the same capacity of the bat- 
tery lead, otherwise the jumper lead may 
burn. 

• This check is likely to produce sparks, 
therefore, make sure no flammable gas or 
fluid is in the vicinity. 

c. When the jumper leads are connected to the 
terminals the respective LED should illumi- 
nate. 

Does not light -► Replace the meter assem- 
bly. 



8-12 



IGNITION SYSTEM 



ELEC 


+ 



IGNITION SYSTEM 

CIRCUIT DIAGRAM 




8-13 



IGNITION SYSTEM 



TROUBLESHOOTING 



The ignition system fails to operate (no 
spark or intermittent spark). 



Check: 

1. Main and ignition fuses 

2. Battery 

3. Spark plugs 

4. Ignition spark gap 

5. Spark plug cap resistance 

6. Ignition coil resistance 

7. Main switch 

8. Engine stop switch 

9. Pickup coil resistance 
10. Wiring connections 

(of the entire ignition system) 

NOTE: 



Before troubleshooting, remove the following 
part(-s): 

1) Seat 

2) Fuel tank 

3) Side cover 

•Troubleshoot with the following special 
tool(-s). 




Dynamic spark tester 

YM-34487 
Ignition checker 

90890-60754 
Pocket tester 

90890-03112 



1 . Main and ignition fuses 



►Check the main and ignition fuses for conti- 
nuity 

Refer to "CHECKING THE FUSES" in 
CHAPTER 3. 



►Are the main and ignition fuses OK? 



o 



YES 



* 



NO 



Replace the fuse(s). 



ELEC 


+ 



2. Battery 



> Check the condition of the battery. 
Refer to "CHECKING THE BATTERY" in 
CHAPTER 3. 



m 



Minimum open-circuit voltage 
12.8 V or more at 20° C 



■ Is the battery OK? 







YES 



* 



NO 



•Clean the battery 

terminals. 
• Recharge or replace 

the battery 



3. Spark plugs 



The following procedure applies to all of the 
spark plugs. 

• Check the condition of the spark plug. 

• Check the spark plug type. 

• Measure the spark plug gap. 

Refer to "CHECKING THE SPARK PLUGS" 
in CHAPTER 3. 




Standard spark plug 

CR9E (NGK) 

U27ESR-N (DENSO) 
Spark plug gap 

0.7 - 0,8 mm 



► Is the spark plug in good condition, it is of the 
correct type, and is its gap within specifica- 
tion? 



o 



YES 



# 



NO 



Re-gap or replace 
the spark plug. 



8-14 



IGNITION SYSTEM 



4. Ignition spark gap 



The following procedure applies to all of the 

spark plugs. 

•Disconnect the spark plug cap from the 

spark plug. 
•Connect the ignition checker ®as shown. 

(D Spark plug cap 
•Set the main switch to "ON". 
• Measure the ignition spark gap (a). 
•Crank the engine by pushing the starter 

switch and gradually increase the spark gap 

until a misfire occurs. 





Minimum ignition spark gap 
6.0 mm 



• Is there a spark and is the spark gap within 
specification? 



* 



NO 







YES 



The ignition system 
is OK. 



5. Spark plug cap resistance 



The following procedure applies to all of the 

spark plug caps. 

•Remove the spark plug cap from the spark 

plug lead. 
•Connect the pocket tester {"£1 x 1 k") to the 

spark plug cap as shown. 
•Measure the spark plug cap resistance. 




ELEC 


+ 




Spark plug cap resistance 
10kftat20°C 



Is the spark plug cap OK? 



o 



YES 



f 



NO 



Replace the spark 
plug cap. 



6. Ignition coil resistance 



The following procedure applies to all of the 

ignition coils. 

•Disconnect the ignition coil leads from the 

wire harness. 
•Connect the pocket tester (£1 x 1) to the 

ignition coil as shown. 



Positive tester probe - 
Negative tester probe 



red/black 
► orange (gray) 




► Measure the primary coil resistance. 




Primary coil resistance 
1.87 ~ 2.53ftat20°C 



► Connect the pocket tester (CI x 1k) to the 
ignition coil as shown. 



Positive tester probe -+ spark plug lead 
Negative tester probe -+ spark plug lead 




► Measure the secondary coil resistance. 



8-15 



IGNITION SYSTEM 




Secondary coil resistance 
12 ~ 18kaat20°C 



Is the ignition coil OK? 







YES 



* 



NO 



Replace the ignition 
coil. 



7. Main switch 



►Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES" 



• Is the main switch OK? 



o 



YES 



* 



NO 



Replace the main 
switch. 



8. Engine stop switch 



► Check the engine stop switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



• Is the engine stop switch OK? 



o 



YES 



# 



NO 



Replace the right 
handlebar switch. 



ELEC 


+ 



9. Pickup coil resistance 



• Disconnect the pickup coil coupler from the 

wire harness. 
•Connect the pocket tester (£1 x 100) to the 

pickup coil terminal as shown. 



Positive tester probe -► gray ® 
Negative tester probe -+ black (2 




•Measure the pickup coil resistance. 




Pickup coil resistance 
248 ~ 372 a at 20°C 
(between gray and black) 



•Is the pickup coil OK? 



o 



YES 



f 



NO 



Replace the pickup 
coil. 



10. Wiring 



►Check the entire ignition system's wiring. 
Refer to "CIRCUIT DIAGRAM". 

► Is the ignition system's wiring properly con- 
nected and without defects? 



f 



NO 







YES 



Properly connect or 
repair the ignition 
system's wiring. 



Replace the ignitor 
unit. 



8-16 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 



ELECTRIC STARTING SYSTEM 

CIRCUIT DIAGRAM 




8-17 



ELECTRIC STARTING SYSTEM 




.<S> 



© 



O \ 




5= 



1 1 I I I I I I 1 l l I 



'» H l H 



Ui® 



®. 



&x 



j 



X X X X X 



» I I I LN 



A® ®A 



ELEC 


+ 



STARTING CIRCUIT CUTOFF SYSTEM OP- 
ERATION 

If the engine stop switch is set to "Q " and the 
main switch is set to "ON" (both switches are 
closed), the starter motor can only operate if at 
least one of the following conditions is met: 
•The transmission is in neutral (the neutral 
switch is closed). 

•The clutch lever is pulled to the handlebar 
(the clutch switch is closed) and the side- 
stand is up (the sidestand switch is closed). 

The starting circuit cutoff relay prevents the 
starter motor from operating when neither of 
these conditions has been met. In this instance, 
the starting circuit cutoff relay is open so current 
cannot reach the starter motor. When at least 
one of the above conditions has been met the 
starting circuit cutoff relay is closed and the en- 
gine can be started by pressing the start switch. 



i i i i 



WHEN THE TRANSMISSION IS IN 
NEUTRAL 

^szsza WHEN THE SIDESTAND IS UP AND 
THE CLUTCH LEVER IS PULLED TO 
THE HANDLEBAR 

© Battery 

© Fuse (main) 

© Main switch 

(4) Fuse (ignition) 

© Engine stop switch 

© Starting circuit cutoff relay 

© Diode 

(D Clutch switch 

© Sidestand switch 

@ Neutral switch 

© Start switch 

© Starter relay 

© Starter motor 



8-18 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 



TROUBLESHOOTING 



The starter motor fails to turn. 



Check: 

1. Main and ignition fuses 

2. Battery 

3. Starter motor 

4. Starting circuit cutoff relay 

5. Starter relay 

6. Main switch 

7. Engine stop switch 

8. Neutral switch 

9. Sidestand switch 

10. Clutch switch 

11. Start switch 

12. Wiring connections 

(of the entire starting system) 

NOTE: 



• Before troubleshooting, remove the following 
part(-s): 

1) Seat 

2) Fuel tank 

3) Side cover 

►Troubleshoot with the following special tool(-s). 



v- 



Pocket tester 
90890-03112 



1 . Main and ignition fuses 



► Check the main and ignition fuses for conti- 
nuity. 

Refer to "CHECKING THE FUSES" in 
CHAPTER 3. 



►Are the main and ignition fuses OK? 



o 



YES 



f 



NO 



Replace the fuse (s). 



2. Battery 



> Check the condition of the battery. 
Refer to "CHECKING THE BATTERY" in 
CHAPTER 3. 



a 



Minimum open-circuit voltage 
12.8 Vor more at 20°C 



Is the battery OK? 



o 



YES 



\ 



NO 



•Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



3. Starter motor 



» Connect the positive battery terminal ® and 
starter motor lead (2) with a jumper lead (3). 




A WARNING 



•A wire that is used as a jumper lead must 
have at least the same capacity or more as 
that of the battery lead, otherwise the 
jumper lead may burn. 

•This check is likely to produce sparks, 
therefore make sure nothing flammable is 
in the vicinity. 



Does the starter motor turn? 



o 



YES 



# 



NO 



Repair or replace the 
starter motor. 



8-19 



ELECTRIC STARTING SYSTEM 



4. Starting circuit cutoff relay 



•Disconnect the starting circuit cutoff relay 
coupler from the wire harness. 

•Connect the pocket tester (Qxl) and bat- 
tery (12 V) to the starting circuit cutoff relay 
coupler as shown. 



Positive battery lead - 
Negative battery lead 



red/black ® 
f black/yellow (2) 



Positive tester probe - 
Negative tester probe 



blue/white 
► black (4) 




L/R 


L/W 


G/W 




>^ 




R/B 


B 


B/L 


W 


B/R 


UW 


Lg 


R/W 


L/B 


L/Y 


Sb 


B/Y 


Sb/W 



►Does the starting circuit cutoff relay have 
continuity between blue/white and black? 



o 



YES 



f 



NO 



Replace the starting 
circuit cutoff relay. 



ELEC 


+ 



GX 




® 


dr 


\ 


/ 




n 


r 


V 


^® 




J 

R 


R 




UW 


R/W 








•Does the starter relay have continuity be- 
tween red and red? 







YES 



# 



NO 



Replace the starter 
relay. 



6. Main switch 



> Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



' Is the main switch OK? 



o 



YES 



* 



NO 



Replace the main 
switch. 



5. Starter relay 



• Disconnect the starter relay coupler from the 
wireharness. 

•Connect the pocket tester {£1 x 1) and bat- 
tery (12 V) to the starter relay coupler as 
shown. 



Positive battery lead - 
Negative battery lead 



blue/white ® 
f red /white (2) 



Positive tester probe -► red (3) 
Negative tester probe -► red (4) 



7. Engine stop switch 



* Check the engine stop switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



■ Is the engine stop switch OK? 



o 



YES 



* 



NO 



Replace the right 
handlebar switch. 



8-20 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 



8. Neutral switch 



•Check the neutral switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the neutral switch OK? 



o 



YES 



t 



NO 



Replace the neutral 
switch. 



9. Sidestand switch 



•Check the sidestand switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the sidestand switch OK? 



o 



YES 



t 



NO 



Replace the side- 
stand switch. 



12. Wiring 



►Check the entire starting system's wiring. 
Refer to "CIRCUIT DIAGRAM". 



• Is the starting system's wiring properly con- 
nected and without defects? 



o 



YES 



t 



NO 



The starting system 
circuit is OK? 



Properly connect or 
repair the starting 
system's wiring. 



10. Clutch switch 



►Check the clutch switch for continuity. 
Refer to "CHECKING THE SWITCHES" 



• Is the clutch switch OK? 



o 



YES 



f 



NO 



Replace the clutch 
switch. 



1 1 . Start switch 



►Check the start switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



• Is the start switch OK? 



o 



YES 



f 



NO 



Replace the right 
handlebar switch. 



8-21 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 



STARTER MOTOR 




Order 


Job/Part 


Q'ty 


Remarks 


1 
2 


Removing the starter motor 

Carburetor 
Starter motor lead 
Starter motor/O-ring 


1 
1/1 


Remove the parts in the order listed. 
Refer to "CARBURETOR" in chapter 7. 

For installation, reverse the removal 
procedure. 



8-22 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 



XI 10Nm(1.0m«kg) 



5 Nm (0.5 rrvkg) 




Order 


Job/Part 


Q'ty 


Remarks 




Disassembling the starter motor 




Disassemble the parts in the order listed. 


(T) 


Starter motor front cover 






® 


Lock washer 






® 


Oil seal 




Refer to "ASSEMBLING THE STARTER 


Bearing 




MOTOR". 


© 


Washer set 




NOTE: 


© 


Starter motor rear cover 




Be sure to remove the installation nut on 


(?) 


Washer set 




brush #1 first. 


(D 


Brush seat (alonq with the brushes) 






(D 


Armature assembly 






© 


Brush holder (along with the brushes) 






<S> 


O-ring 


2 




@ 


Starter motor yoke 


1 


For assembly reverse the disassembly 
procedure. 



8-23 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 



EAS00769 

CHECKING THE STARTER MOTOR 

1. Check: 
•commutator 
Dirt -+ Clean with 600-grit sandpaper. 




2. Measure: 
• commutator diameter (a) 
Out of specification -+ Replace the starter 
motor. 




Commutator wear limit 
27 mm 



3. Measure: 
•mica undercut® 

Out of specification -+ Scrape the mica to the 
proper measurement with a hacksaw blade 
that has been grounded to fit the commuta- 
tor. 




Mica undercut 
0,7 mm 



NOTE: 

The mica must be undercut to ensure proper op- 
eration of the commutator. 




4. Measure: 
•armature assembly resistances (commuta- 
tor and insulation) 

Out of specification -► Replace the starter 
motor. 

a. Measure the armature assembly resistances 
with the pocket tester. 



v- 



Pocket tester 
90890-08112 



§4 



Armature coil 
Commutator resistance © 

0.025 ~ 0.035 ft at 20 °C 
Insulation resistance (2) 

Above 1MQ at 20°C 



8-24 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 



b. If any resistance is out of specification, re- 
place the starter motor. 




i£> _>» 











(a) 





5. Measure: 
•brush length® 
Out of specification 
as a set. 



Replace the brushes 




Brush length wear limit 
4 mm 



6. Measure: 
•brush spring force 
Out of specification 
springs as a set. 



Replace the brush 




Brush spring force 
7.65 ~ 10.01 N 



7. Check: 
•gear teeth 
Damage/wear 



Replace the gear. 



EAS00772 

ASSEMBLING THE STARTER MOTOR 

1. Install: 
•armature 
• brush seat © 

NOTE: 

Align the tab® on the brush seat with the slot® 
in the starter motor rear cover. 



8-25 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 




2. Install: 
• starter motor front cover ® 
•starter motor rear cover® 
•0-ring(c 

NOTE: — 



Align the match marks (a) on the starter motor 
yoke with the match marks © on the front and 
starter motor rear covers. 



8-26 



CHARGING SYSTEM 



ELEC 


+ 



CHARGING SYSTEM 

CIRCUIT DIAGRAM 



R/W 



R/B 



G/Y 



ID 



R/W 



[[R/B 



G/Y 



L/W 




© Rectifire/reguretor 
© AC magneto 
© Battery 
© Fuse (main) 



8-27 



CHARGING SYSTEM 



TROUBLESHOOTING 



The battery is not being charged. 



Check: 

1. Main fuse 

2. Battery 

3. Charging voltage 

4. Stator coil resistance 

5. Wiring connections 

(of the entire charging system) 
NOTE: 



• Before troubleshooting, remove the following 
part(-s): 

1) Seat 

2) Fuel tank 

3) Side cover 

•Troubleshoot with the following special 
tool(-s). 




Engine tachometer 
90890-03113 

Pocket tester 
90890-03112 



1 . Main fuses 



►Check the fuses for continuity. 
Refer to "CHECKING THE FUSES" in 
CHAPTER 3. 



•Are the fuses OK? 



o 



YES 



# 



NO 



Replace the fuse (s). 



2. Battery 



•Check the condition of the battery. 
Refer to "CHECKING THE BATTERY" in 
CHAPTER 3. 



Si 



Minimum open-circuit voltage 
12.8 V or more at 20°C 



■ Is the battery OK? 



ELEC 


I" + 







YES 



t 



NO 



•Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



3. Charging voltage 



• Connect the engine tachometer to the spark 

plug lead of cylinder #1 . 
•Connect the pocket tester (DC 20 V) to the 

battery as shown. 



Positive tester probe -► 

positive battery terminal 
Negative tester probe -► 

negative battery terminal 







DC20V 






















-i i+- 

















•Start the engine and let it run at approxi- 
mately 5,000 r/min. 
•Measure the charging voltage. 



m 



Charging voltage 
14 Vat 5,000 r/min 



NOTE: 

Make sure the battery is fully charged. 

• Is the charging voltage within specification? 



f 



NO 







YES 



The charging circuit 
is OK. 



8-28 



CHARGING SYSTEM 



ELEC 


+ 



4. Stator coil resistance 



• Remove the generator cover. 
•Connect the pocket tester (£2 x 1) to the sta- 
tor coils as shown. 



Positive tester probe -► white ® 
Negative tester probe -► white (D 



Positive tester probe -+ white (3) 
Negative tester probe -► white ® 




•Measure the stator coil resistances. 



B. 



Stator coil resistance 
0.27 ~ 0.33 a at 20°C 



■ Is the stator coil OK? 







YES 



f 



NO 



Replace the stator 
coil assembly. 



5. Wiring 



►Check the wiring connections of the entire 
charging system. 
Refer to "CIRCUIT DIAGRAM". 



•Is the charging system's wiring properly 
connected and without defects? 



o 



YES 



t 



NO 



Replace the rectifi- 
er/regulator. 



Properly connect or 
repair the charging 
system's wiring. 



8-29 



LIGHTING SYSTEM 



ELEC 


+ 



LIGHTING SYSTEM 

CIRCUIT DIAGRAM 



© Main switch 

© Battery 

® Fuse (main) 

© Hi-beam indicator light 

© Meter light 

@ Headlight switch 

© Pass switch 



@ Dimmer switch 

© Headlight 

©Tail/brake light 

© Fuse (Alarm) 

© Fuse (headlight) 

@ Headlight relay (on/off) 

© Headlight relay (dimmer) 






© 




s 




1 




I 


1 




i 



< if 



i©j 




8-30 



LIGHTING SYSTEM 



EAS00781 

TROUBLESHOOTING 



Any of the following fail to light: headlight, 
high beam indicator light, taillight, auxilia- 
ry light or meter light. 



Check: 

1 . Main, headlight and alarm fuses 

2. Battery 

3. Main switch 

4. Headlight switch 

5. Dimmer switch 

6. Pass switch 

7. Headlight relay (on/off) (for EUR) 

8. Headlight relay (dimmer) 

9. Wiring connections 

(of the entire charging system) 

NOTE: 



• Before troubleshooting, remove the following 
part(-s): 

1) Seat 

2) Fuel tank 

3) Side cover 

•Troubleshoot with the following special 
tool(-s). 




Pocket tester 
90890-03112 



1 . Main, headlight and alarm fuses 



> Check the main, headlight and alarm fuses 
for continuity 

Refer to "CHECKING THE FUSES" in 
CHAPTER 3. 



•Are the main, headlight and alarm fuses 
OK? 



o 



YES 



t 



NO 



Replace the fuse (s). 



2. Battery 



• Check the condition of the battery. 
Refer to "CHECKING THE BATTERY" in 
CHAPTER 3. 



II 



Minimum open-circuit voltage 
12.8 Vor moreat20°C 



• Is the battery OK? 



ELEC 


I" + 







YES 



# 



NO 



•Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



3. Main switch 



•Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the main switch OK? 



o 



YES 



f 



NO 



Replace the main 
switch. 



4. Headlight switch 



•Check the headlight switch for continuity 
Refer to "CHECKING THE SWITCHES". 



Is the headlight switch OK? 



o 



YES 



f 



NO 



The headlight switch 
is faulty. Replace the 
right handlebar 

switch. 



5. Dimmer switch 



■ Check the dimmer switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the dimmer switch OK? 



o 



YES 



t 



NO 



The dimmer switch is 
faulty. Replace the 
left handlebar switch. 



8-31 



LIGHTING SYSTEM 



6. Pass switch 



►Check the pass switch for continuity. 
Refer to "CHECKING THE SWITCHES" 



• Is the pass switch OK? 



o 



YES 



f 



NO 



The pass switch is 
faulty. 

Replace the left han- 
dlebar switch. 



7. Headlight relay (on/off) (for EUR) 



• Disconnect the headlight relay (on/off) from 
the coupler. 

•Connect the pocket tester (£1 x 1) and bat- 
tery (12 V) to the headlight relay (on/off) 
coupler as shown. 



Positive battery lead - 
Negative battery lead 



blue/black ® 
f black (D 



Positive tester probe - 
Negative tester probe 



red/yellow (3) 
f black/blue @ 



L/B 



Z± 



R/Y 



B/L 



V 



B 




► Does the headlight relay (on/off) have conti- 
nuity between red/yellow and black/blue? 



o 



YES 



# 



NO 



Replace the head- 
light relay (on/off). 



8. Headlight relay (dimmer) 



•Disconnect the headlight relay (dimmer) 
from the coupler. 

•Connect the pocket tester (£1 x 1) and bat- 
tery (12 V) to the headlight relay (dimmer) 
coupler as shown. 



ELEC 


+ 



Low-beam 

Positive tester probe - 

Negative tester probe 



black/blue® 
► black/green (2) 





A 




A 


y° 




B/L 
B/Y 








' 




Y 


B/G 


B 






X 






V 








V 


\ 



Hi-beam 

Positive battery lead -► yellow ® 

Negative battery lead -+ black (2) 



Positive tester probe - 
Negative tester probe 



black/blue (3) 
► black/yellow® 



A 





B/L 
B/Y 




© 








Y 


B/G 


B 




\ 




x 




V 








V 





>Does the headlight rrelay (dimmer) have 
continuity? 



o 



YES 



t 



NO 



Replace the head- 
light relay (dimmer). 



9. Wiring 



•Check entire lighting system's wiring. 
Refer to "CIRCUIT DIAGRAM". 



» Is the lighting system's wiring properly con- 
nected and without defects? 



o 



YES 



# 



NO 



Check the condition 
of each of the lighting 
system's circuits. 
Refer to "CHECK- 
ING THE LIGHTING 
SYSTEM". 



Properly connect or 
repair the lighting 
system's wiring. 



8-32 



LIGHTING SYSTEM 



ELEC 


+ 



EAS00788 

CHECKING THE LIGHTING SYSTEM 

1. The headlight and the high beam indicator 
light fail to come on. 



1 . Headlight buld and scocket 



•Check the headlight bulb and socket for 
continuity. 



►Are the headlight bulb and socket OK? 



o 



YES 



f 



NO 



Replace the headlight 
bulb, socket or both 



2. Voltage 



•Connect the pocket tester (DC 20 V) to the 
headlight and high beam indicator light cou- 
plers as shown. 



[A] When the dimmer switch is set to " 10 ". 
\B\ When the dimmer switch is seto to " =0 "■ 



Headlight 
Positive tester probe -► 

black/yellow® or black/green(2) 
Negative tester probe -► black (3) 
High beam indicator light 
Positive tester probe -► 

black/yellow® 
Negative tester probe -► black (5) 



Headlight coupler (wire harness side) 



H 



DC20V 



- VS^ + 



B/G 



B/Y 



Meter light coupler (wire harness side) 

(5) 




•Set the main switch to "ON". 
•Set the light switch to "ON". 
• Set the dimmer switch to " f " or " 10 ". 
•Measure the voltage (12 V) (wire harness 
side). 



• Is the voltage within specification? 



o 



YES 



f 



NO 



This circuit is OK. 



The wiring circuit 
from the main switch 
to the headlight cou- 
pler is faulty and 
must be repaired. 



2. The meter light fails to come on. 



1 . Meter light bulb and socket 



•Check the meter light bulb and socket for 
continuity. 



►Are the meter light bulb and socket OK? 



o 



YES 



f 



NO 



Replace the meter 
light bulb, socket of 
both. 



2. Vollage 



> Connect the pocket tester (DC 20 V) to the 
meter light coupler (wire harness side) as 
shown. 



Positive tester probe -► blue © 
Negative tester probe -► black (2 




8-33 



LIGHTING SYSTEM 



•Set the main switch to "ON". 
•Set the light switch to "PO" or "ON". 
• Measure the voltage (1 2 V) of blue© on the 
meter light coupler (wire harness side). 



■ Is the voltage within specification? 







YES 



f 



NO 



This circuit is OK. 


The wiring circuit from 
the main switch to the 
meter light coupler is 
faulty and must be re- 
paired. 





3. The tail/brake light fails to come on. 



1 . Tail/brake light bulb and socket 



► Chek the tail/brake light bulb and socket for 
continuity. 



►Are the tail/brake light bulb and socket OK? 



o 



YES 



# 



NO 



Replace the tail/brake 
light bulb, socket or 
both. 



ELEC 


+ 



•Set the main switch to "ON". 

•Set the light switch to TO" or "ON". 

• Measure the voltage (1 2 V) of blue/red ® on 

the tail/brake light coupler (tail/brake light 

side). 



Is the voltage within specification? 



o 



YES 



f 



NO 



This circuit is OK. 


The wiring circuit from 
the main switch to the 
tail/brake light coupler 
is faulty and must be 
repaired. 





2. Voltage 


•Connect the pocket tester (DC 20 V) to the 
tail/brake light coupler (wire harness side) 
as shown. 


Positive tester probe - 
Negative tester probe 


+ blue/red ® 

-+ black <D 




n=n 


^® 


(^ 


Y 

/ 
/ 


L/R 

5 

/ 
/ 
/ 



8-34 



SIGNAL SYSTEM 



ELEC 


+ 



SIGNAL SYSTEM 

CIRCUIT DIAGRAM 




© 




s 




1 

8 




i 


I 




i 



< 11 
® — y= 

nm 

<1± 



8-35 



SIGNAL SYSTEM 



ELEC 


+ 



(T) Main switch 

(5) Battery 

Fuse (main) 

(D Starting circuit cutoff relay 

© Neutral switch 

© Fuel level warning light 

@ Oil level warning light 

© Neutral indicator light 

© Combination meter 

© Fuel gauge 

© Turn signal indicator light (left) 

© Turn signal indicator light (right) 

© Oil level gauge 

© Fuel sender 

©Turn signal relay 

© Front brake light switch 

©Horn 

@ Horn switch 

© Hazard switch 

©Turn signal switch 

@ Front turn signal light (left) 

© Front turn signal light (right) 

© Rear turn signal light (left) 

© Rear turn signal light (right) 

©Tail/brake light 

© Fuse (turn signal) 

© Fuse (ignition) 

© Fuse (alarm) 

© Rear brake light switch 



8-36 



SIGNAL SYSTEM 



ELEC 


+ 



TROUBLESHOOTING 



•Any of the following fail to come on: turn 
signal light, brake light or indicator light. 
•The horn fails to sound. 



Check: 

1 . Main, signal, alarm and clock fuses 

2. Battery 

3. Main switch 

4. Wiring connections 

(of the entire signal system) 

NOTE: 



•Before troubleshooting, remove the following 
part(s): 

1) Seat 

2) Fuel tank 

3) Front cowling 

4) Side cover 

•Troubleshoot with the following special tool(s). 




Pocket tester 
90890-03112 



1. Main, signal, alarm and ignition fuses 



•Check the main, signal, alarm and ignition 
fuses for continuity. 

Refer to "CHECKING THE FUSES" in 
CHAPTER 3. 



•Are the main, signal, alarm and ignition 
fuses OK? 



o 



YES 



f 



NO 



Replace the fuse (s). 



2. Battery 



•Check the condition of the battery. 
Refer to "CHECKING THE BATTERY" in 
CHAPTER 3. 



II 



Minimum open-circuit voltage 
12.8 V or more at 20°C 



■ Is the battery OK? 







YES 



f 



NO 



•Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



3. Main switch 



►Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the main switch OK? 



o 



YES 



# 



NO 



Replace the main 
switch. 



4. Wiring 



» Check the entire signal system's wiring. 
Refer to "CIRCUIT DIAGRAM". 



•Is the signaling system's wiring properly 
connected and without defects? 



o 



YES 



* 



NO 



Check the condition 
of each of the signal- 
ing system's circuits. 
Refer to "CHECK- 
ING THE SIGNAL- 
ING SYSTEM". 



Properly connect or 
repair the signaling 
system's wiring. 



CHECKING THE SIGNAL SYSTEM 

1 . The horn fails to sound. 



1 . Horn switch 



•Check the horn switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the horn switch OK? 



o 



YES 



f 



NO 



Replace the left han- 
dlebar switch. 



2. Voltage 



•Connect the pocket tester (DC 20 V) to the 
horn connector at the horn terminal as 
shown. 



8-37 



Positive tester probe -► pink ® 
Negative tester probe -► black 




•Set the main switch to "ON". 
•Push the horn switch. 
•Measure the voltage (12 V) of pink at the 
horn terminal. 



• Is the voltage within specification? 



o 



YES 



f 



NO 



The wiring circuit 
from the main switch 
to the horn connector 
is faulty and must be 
repaired. 



3. Horn 



► Disconnect the black connector at the horn 
terminal. 

► Connect a jumper lead ® to the horn termi- 
nal and ground the jumper lead. 

►Set the main switch to "ON". 
►Push the horn switch. 



• Does the horn sound? 




_^D 



* 



NO 







YES 



The horn is OK. 



SIGNAL SYSTEM 



ELEC 


+ 



4. Voltage 



•Connect the pocket tester (DC 20 V) to the 
horn connector at the black terminal as 
shown. 



Positive tester probe -► black® 
Negative tester probe -+ ground 




•Set the main switch to "ON". 
• Measure the voltage (1 2 V) of black® at the 
horn terminal. 



■ Is the voltage within specification? 



o 



YES 



# 



NO 



Repair or replace the 
horn. 



Replace the horn. 



2. The tail/brake light fails to come on. 



1 . Tail/brake light bulb and socket. 



> Check the tail/brake light bulb and socket for 
continuity. 



► Are the tail/brake light bulb and socket OK? 



o 



YES 



# 



NO 



Replace the tail/brake 
light bulb, socket or 
both. 



2. Brake switches 



► Check the brake light switches for continuity. 
Refer to "CHECKING THE SWITCHES". 



■ Is the brake light switch OK? 



o 



YES 



f 



NO 



8-38 



Replace the brake 
light switch. 



3. Voltage 



•Connect the pocket tester (DC 20 V) to the 
tail/brake light coupler (wire harness side) 
as shown. 



Positive tester probe - 
Negative tester probe 



yellow ® 

> black (D 




•Set the main switch to "ON". 

• Pull in the brake lever or push down on the 
brake pedal. 

• Measure the voltage (1 2 V) of yellow ® on the 
tail/brake light coupler (wire harness side). 



» Is the voltage within specification? 



o 



YES 



* 



NO 



This circuit is OK. 


The wiring circuit from 
the main switch to the 
tail/brake light coupler 
is faulty and must be 
repaired. 





3. The turn signal light, turn signal indicator 
light or both fail to blink. 



1 . Turn signal indicator light bulb and socket 



►Check the turn signal light bulb and socket 
for continuity. 



► Are the turn signal light bulbs and socket OK? 



o 



YES 



# 



NO 



Replace the turn sig- 
nal light bulb, socket 
or both. 



SIGNAL SYSTEM 



ELEC 


+ 



2. Turn signal switch 



►Check the turn signal switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the turn signal switch OK? 



o 



YES 



# 



NO 



Replace the left han- 
dlebar switch. 



3. Voltage 



•Connect the pocket tester (DC 20 V) to the 
turn signal relay coupler (wire harness side) 
as shown. 



Positive tester probe -+ brown (T) 
Negative tester probe -► ground 



n n 



G> 



HBr/W 



Br 



►Set the main switch to "ON". 
►Measure the voltage (12 V) on brown® at 
the turn signal relay coupler (wire harness 
side). 



Is the voltage within specification? 



o 



YES 



# 



NO 



The wiring circuit 
from the main switch 
to the turn signal 
relay coupler is faulty 
and must be re- 
paired. 



8-39 



SIGNAL SYSTEM 



ELEC 


+ 



4. Voltage 



•Connect the pocket tester (DC 20 V) to the 
flasher relay coupler (wire harness side) as 
shown. 



Positive tester probe - 
Negative tester probe 



brown/white ® 
f ground 



G> 



U"Br/W 



Br 



•Set the main switch to "ON". 
• Set the turn signal switch to " O " or " <p ". 
•Measure the voltage (12 V) on brown/white 
® at the turn signal relay coupler (wire har- 
ness side). 



• Is the voltage within specification? 



o 



YES 



# 



NO 



The turn signal relay 
is faulty and must be 
replaced. 



5. Voltage 


•Connect the pocket tester 


(DC 20 V) to the 


turn signal light connector (wire harness 


side) as shown. 






[A] Rear turn signal light 






[B]Turn signal indicator light 






Left turn signal light 






Positive tester probe -» 


chocolate 


CD 


Negative tester probe - 


+ ground 




Right turn signal light 






Positive tester probe -> 


dark green 


(2) 


Negative tester probe - 


+ ground 






w 




•Set the main switch to "ON". 

• Set the turn signal switch to " c£> " or " O ". 

• Measure the voltage (1 2 V) of the chocolate 
® or dark green (2) at the turn signal light 
connector (wire harness side). 



• Is the voltage within specification? 



o 



YES 



* 



NO 



This circuit is OK. 



The wiring circuit 
from the turn signal 
switch to the turn sig- 
nal light connector is 
faulty and must be 
repaired. 



4. The neutral indicator light fails to come on. 



1 . Neutral indicator light bulb and socket 



►Check the neutral indicator light bulb and 
socket for continuity. 



► Are the neutral indicator light bulb and sock- 
et OK? 



o 



YES 



f 



NO 



Replace the neutral 
indicator light bulb, 
socket or both. 



2. Neutral switch 



►Check the neutral switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the neutral switch OK? 



o 



YES 



f 



NO 



Replace the neutral 
switch. 



8-40 



3. Voltage 



•Connect the pocket tester (DC 20 V) to the 
meter light bulb coupler (wire harness side) 
as shown. 



Positive tester probe -► brown ® 
Negative tester probe -► ground 



^x 



L/Y R/G B Br L Dg Ch B/Y 



B/R Sb/W W Y/B B/L G/R G G/B 



•Set the main switch to "ON". 
•Measure the voltage (12 V). 



» Is the voltage within specification? 



o 



YES 



f 



NO 



This circuit is OK. 



The wiring circuit 
from the main switch 
to the meter light bulb 
coupler is faulty and 
must be repaired. 



SIGNAL SYSTEM 



ELEC 


+ 



2. Engine oil level switch 



► Drain the engine oil and remove the engine 
oil level switch from the oil pan. 

►Check the engine oil level switch for conti- 
nuity. 
Refer to "CHECKING THE SWITCHES". 



Is the engine oil level switch OK? 



o 



YES 



t 



NO 



Replace the engine 
oil level switch. 



3. Wiring 



•Check the entire signal system's wiring. 
Refer to "CIRCUIT DIAGRAM". 



•Is the signaling system's wiring properly 
connected and without defects? 



o 



YES 



# 



NO 



Replace the meter 
unit. 



Properly connect or 
repair the signaling 
system's wiring. 



5. The oil level warning light fails to come on. 



1 . Oil level warning light bulb and socket 



•Check the oil level warning light bulb and 
socket for continuity. 



►Are the oil level warning light bulb and sock- 
et OK? 



o 



YES 



f 



NO 



Replace the oil level 
warning light bulb, 
socket or both. 



8-41 



5. The fuel level gauge fails to operate. 



1. Fuel sender 



► Remove the fuel sender from the fuel tank. 

► Connect the pocket tester to the fuel sender 
coupler (wire harness side) as shown. 



Positive tester probe -► green ® 
Negative tester probe -► black (§) 




Measure the fuel sender resistances. 



a. 



Fuel sender resistance (up position 

®)(fixi) 

4 ~ 10£2at20°C 
Fuel sender resistance (down posi- 
tion® ) (O x 10) 

90 ~ 100nat20°C 



• Is the fuel sender OK? 







YES 



f 



NO 



Replace the fuel 
sender. 



2. Voltage 



•Connect the pocket tester (DC 20 V) to the 
meter light coupler (wire harness side) as 
shown. 



Positive tester probe -► brown ® 
Negative tester probe -► black (2) 





\ 


y\ 








L/Y 


R/G 


B 


Br 


L 


Dg 


Ch 


B/Y 


B/R 


Sb/W 


W 


Y/B 


B/L 


G/R 


G 


G/B 








/ 
/ 
/ 


/ 
/ 
/ 




\ 


D 



SIGNAL SYSTEM 



ELEC 


+ 



►Set the main switch to "ON". 
► Measure the voltage (1 2 V) of brown ® on 
the meter light coupler (wire harness side). 



Is the voltage within specification? 



o 



YES 



t 



NO 



Check 


the 


wiring 


connections 


of 


the 


entire 


signaling 


sys- 


tern. 









3. Fuel level gauge 



•Set the main switch to "ON". 

• Move the float up ® or down (2) . 

• Check that the fuel level gauge needle 
moves to "F" or "E". 



® 




NOTE: 

Before reading the fuel level gauge, leave 
the float in one position (either up or down) 
for at least three minutes. 



► Does the fuel level gauge needle move ap- 
propriately? 



o 



YES 



* 



NO 



Replace the fuel lev- 
el gauge. 



4. Wiring 



•Check the entire signaling system's wiring. 
Refer to "CIRCUIT DIAGRAM". 



8-42 



COOLING SYSTEM 



ELEC 


+ 



EAS00807 

COOLING SYSTEM 

CIRCUIT DIAGRAM 




© 
© 
© 



Main switch 

Battery 

Fuse (main) 

Thermo unit 

Combination meter 

Water temp warning light 

Fues (fan) 

Fan motor relay 

Fan motor 



© 




s 




1 
1 




I 


' 




i 



® 


< 


i 


| 




i 


< 




1 







8-43 



COOLING SYSTEM 



ELEC 


+ 



TROUBLESHOOTING 



• The radiator fan motor fails to turn. 

• The water temperature gauge needle 
fails to move when the engine is warm. 



Check: 

1 . Main and radiator fan motor fuses 

2. Battery 

3. Main switch 

4. Radiator fan motor 

5. Thermo unit 

6. Wiring connections 

(the entire cooling system) 

NOTE: 



•Before troubleshooting, remove the following 
part(-s). 

1) Seat 

2) Fuel tank 

• Troubleshoot with the following special tool(s). 




Pocket tester 
90890-03112 



1 . Main and radiator fan motor fuses 



► Check the main and radiator fan motor fuses 
for continuity. 

Refert to "CHECKING THE FUSES" in 
CHAPTER 3. 



•Are the main and radiator fan motor fuses 
OK? 



o 



YES 



f 



NO 



Replace the fuse (s). 



2. Battery 



•Check the condition of the battery. 
Refer to "CHECKING THE BATTERY" in 
CHAPTER 3. 



a. 



Minimum open-circuit voltage 
12.8 V or more at 20°C 



Is the battery OK? 







YES 



# 



NO 



•Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



3. Main switch 



•Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the main switch OK? 



o 



YES 



* 



NO 



Replace the main 
switch. 



4. Radiator fan motor 



•Disconnect the rediator fan motor coupler 
from the wire harness. 
•Connect the battery (12 V) as shown. 



Positive battery lead -► blue (T) 
Negative battery lead -► black Q 




Does the rediator fan motor turn? 



o 



YES 



# 



NO 



The radiator fan mo- 
tor is faulty and must 
be replaced. 



8-44 



COOLING SYSTEM 



ELEC 


+ 



5. Thermo unit 



• Remove the thermo unit from the thermostat 
housing. 

• Connect the pocket tester (flx1)to the ter- 
mo unit ®as shown. 

• Immerse the termo unit in a container filled 
with coolant (2). 

NOTE: 



Make sure the termo unit terminals do not 
get wet. 



► Place a thermometer (3) in the coolant. 
►Slowly heat the coolant, and then let it cool 
to the specified temperature indicated in the 
table. 

►Check the thermo unit for continuity at the 
temperatures indicated in the table. 




© _ O 



Q 



u^ 



j 




Termo unit resistance 
80°C: 3.41 ~ 4.00 O 
105°C:1.65 ~ 1.86H 



A WARNING 



•Handle the termo unit with special care. 

•Never subject the thermo unit to strong 
shocks. If the thermo unit is dropped, re- 
place it. 



X 



Thermo unit 

15Nm(1.5irrkg) 
Three bond sealock® 10 



» Does the thetmo unit operate properly? 



o 



YES 



t 



NO 



Replace the thermo 
unit. 



6. Fan motor relay 



• Disconnect the fan motor relay coupler from 
the wire harness. 

•Connect the pocket tester (£1 x 1) and bat- 
tery (12 V) to the fan mtor relay coupler as 
shown. 



Positive battery terminal -► brown ® 
Negative battery terminal -► 

green/black(2) 



Positive tester probe -► brown (2 
Negative tester probe -► blue (4) 





Br 

L 




Br 





G/B 




V 





^^3) 



v 



:.^® 



► Does the fan motor relay have continuity be- 
tween brown and blue? 



o 



YES 



f 



NO 



Replace the fan mo- 
tor relay. 



7. Wiring 



►Check the entire cooling system's wiring. 
Refer to "CIRCUIT DIAGRAM". 



• Is the cooling system's wiring properly con- 
nected and without defects? 



o 



YES 



# 



NO 



This circuit is OK. 



Properly connect or 
repair the cooling 
system's wiring. 



8-45 



FUEL PUMP SYSTEM 



ELEC 


+ 



FUEL PUMP SYSTEM 

CIRCUIT DIAGRAM 




8-46 



FUEL PUMP SYSTEM 



ELEC 


+ 



FUEL PUMP CIRCUIT OPERATION 

The ignitor unit includes the control unit for the 
fuel pump. 



© Battery 

® Main fuse 

© Main switch 

© Ignition fuse 

® Engine stop switch 

® Ignitor unit 

© Fuel pump relay 

® Fuel pump 




8-47 



FUEL PUMP SYSTEM 



ELEC 


+ 



EAS00816 

TROUBLESHOOTING 



If the fuel pump fails to operate. 



Check: 

1. Main and ignition fuses 

2. Battery 

3. Main switch 

4. Engine stop switch 

5. Starting circuit cutoff relay 
(the fuel pump relay) 

6. Fuel pump 

7. Wiring connections 
(the entire fuel system) 

NOTE: 



•Before troubleshooting, remove the following 
part(-s): 

1) Seat 

2) Fuel tank 

3) Side cover 

Troubleshoot with the following special tool(s). 




Pocket tester 
90890-03112 



1. Main, and ignition fuses 



► Check the main and ignition fuses for conti- 
nuity. 

Refer to "CHECKING THE FUSES" in 
CHAPTER 3. 



►Are the main and ignition fuses OK? 



o 



YES 



# 



NO 



Replace the fuse (s). 



2. Battery 



•Check the condition of the battery. 
Refer to "CHECKING THE BATTERY" in 
CHAPTER 3. 



Sii 



Minimum open-circuit voltage 
12.8 Vor moreat20°C 



• Is the battery OK? 



o 



YES 



t 



NO 



•Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



3. Main switch 



►Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the main switch OK? 



o 



YES 



f 



NO 



Replace the main 
switch. 



4. Engine stop switch 



► Check the engine stop switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the engine stop switch OK? 



o 



YES 



# 



NO 



Replace the right 
handlebar switch. 



5. Starting circuit cutoff relay 



•Disconnect the starting circuit cutoff relay 
coupler from the wire harness. 

• Connect the pocket tester {£1 x 1 ) and bat- 
tery (1 2 V) to the starting circuit cutoff relay 
coupler as shown. 



Positive battery lead - 
Negative battery lead 



red/black ® 
f blue/red (2) 



Positive tester probe - 
Negative tester probe 



red/black (3) 
f black/blue (4) 




L/R 


L/W 


G/W 




>^ 




R/B 


B 


B/L 


W 


B/R 


UW 


Lg 


R/W 


L/B 


L/Y 


Sb 


B/Y 


Sb/W 



► Does the starting circuit cutoff relay have con- 
tinuity between red/black and black/blue? 



o 



YES 



f 



NO 



8-48 



Replace the starting 
circuit cutoff relay. 



FUEL PUMP SYSTEM 



ELEC 


+ 



6. Fuel pump resistance 



•Disconnect the fuel pump coupler from the 

wire harness. 
•Connect the pocket tester (£2 x 1) to the fuel 

pump coupler as shown. 



Positive tester probe - 
Negative tester probe 



black/blue® 
► black (2) 



n- 



B/L 



■ Measure the fuel pump resistance. 



m 



Fuel pump resistance 
4 ~ 30 £1 at 20°C 



Is the fuel pump OK? 



o 



YES 



* 



NO 



Replace the fuel 
pump. 



7. Wiring 



• Check the entire fuel pump system's wiring. 
Refer to "CIRCUIT DIAGRAM". 

•Is the fuel system's wiring properly con- 
nected and without defects? 



o 



YES 



* 



NO 



Replace the ignitor 
unit. 



Properly connect or 
repair the fuel sys- 
tem's wiring. 



8-49 



FUEL PUMP SYSTEM 



ELEC 


+ 



EAS00819 

CHECKING THE FUEL PUMP 



A WARNING 



Gasoline is extremely flammable and under 
certain circumstances there can be a danger 
of an explosion or fire. Be extremely careful 
and note the following points: 
•Stop the engine before refuelling. 

• Do not smoke, and keep away from open 
flames, sparks, or any other source of fire. 

• If you do accidentally spill gasoline, wipe it 
up immediately with dry rags. 

•If gasoline touches the engine when it is 
not, a fire may occur. Therefore, make sure 
that the engine is completely cool before 
performing the following test. 




1. Check: 
•fuel pump operation 



a. Fill the fuel tank. 

b. Put the end of the fuel hose into an open con- 
tainer. 

c. Turn the fuel cock to "ON". 

d. Connect the battery (12 V) to the fuel pump 
coupler as shown. 



Positive battery lead -► black/blue ® 
Negative battery lead -► black (2) 



e. If fuel flows out of the fuel hose, the fuel pump 
is OK. 
If fuel does not flow, replace the fuel pump. 



8-50 



EXUP SYSTEM 



ELEC 


+ 



EAS00827 

EXUP SYSTEM 

CIRCUIT DIAGRAM 




8-51 



EXUP SYSTEM 



ELEC 


+ 



TROUBLESHOOTING 



When the engine speed changes, the 
EXUP servomotor does not operate. 



Procedure 1 
Check: 

1 . EXUP servomotor operation 

(with the EXUP servomotor coupler con- 
nected to the wire harness) 

2. Voltage 

3. EXUP servomotor operation 

(with the EXUP servomotor coupler discon- 
nected from the wire harness) 

4. EXUP servomotor resistance 
(potentiometer resistance) 

5. Wiring connections 

(the entire EXUP system) 
Procedure 2 
Check: 

1 . Main and turn signal fuses 

2. Battery 

3. Main switch 

4. Neutral switch 

5. Engine stop switch 

6. Wiring connections 

(the entire EXUP system) 

NOTE: 

•Before troubleshooting, remove the following 
part(s): 

1) Seat 

2) Fuel tank 

•Troubleshoot with the following special tool(s). 




Pocket tester 
90890-03112 



EAS00829 

Procedure 1 



1 . EXUP servomotor operation (with the 
EXUP servomotor coupler connected to 
the wire harness) 



• Disconnect the EXUP cables at the EXUP 
servomotor pulley side. 
•Start the engine and rev it to 5,000 r/min. 



• Does the EXUP servomotor pulley turn? 



o 



YES 



# 



NO 



Check that the EXUP 
cables are properly 
installed. 

If the connections are 
correct, check the 
EXUP valve and 
cables. Refer to "EX- 
HAUST SYSTEM" in 
chapter 5. 



2. Voltage 



•Connect the pocket tester (DC 20 V) to the 
EXUP servomotor coupler as shown. 



Positive tester probe - 
Negative tester probe 



black/red ® 
► black/yellow (2) 




•Set the main switch to "ON". 
•Measure the voltage (12 V) between 
black/red ® and black/yellow (f) . 



Is the voltage within specification? 



o 



YES 



* 



NO 



Go to Procedure 2. 



8-52 



EXUP SYSTEM 



ELEC 


+ 



3. EXUP servomotor operation (with the 
servomotor coupler disconnected to the 
wire harness) 



• Disconnect the EXUP cables from the EXUP 
servomotor pulley. 

•Disconnect the EXUP servomotor coupler 
from the wire harness. 

•Connect the battery leads to the EXUP ser- 
vomotor coupler as shown. 



Positive battery lead -► black/yellow © 
Negative battery lead -► black/ red (2) 



W/R 



B/Y 



B/L 



B/R 



• Check that the EXUP servomotor pulley ro- 
tates several times. 

CAUTION: 



To prevent damaging the EXUP servomo- 
tor, perform this test within a few seconds 
of connecting the battery. 



• Does the EXUP servomotor pulley turn? 



o 



YES 



f 



NO 



Replace the EXUP 
servomotor. 



4. EXUP servomotor resistance 
(potentiometer resistance) 



•Disconnect the EXUP servomotor coupler 

from the wire harness. 
•Connect the pocket tester (Q x 1 k) to the 

EXUP servomotor coupler. 






1 1 






L 


W/R 


B/L 






B/Y 


B/R 











Positive tester probe - 
Negative tester probe 



blue ® 
► white/red 



►While slowly turning the EXUP servomotor 
pulley, measure the EXUP servomotor re- 
sistance. 



§4 



EXUP servomotor resistance 
(when the pulley is turned once) 

- approximately 7.5 k £1 

(blue- white/red) 



• Is the EXUP servomotor OK? 



o 



YES 



f 



NO 



The EXUP servomo- 
tor is faulty and must 
be replaced. 



5. Wiring 



►Check the entire EXUP system's wiring. 
Refer to "CIRCUIT DIAGRAM". 



•Is the EXUP system's wiring properly con- 
nected and without defects? 



o 



YES 



* 



NO 



Replace the ignitor 
unit. 



Properly connect or 
repair the EXUP sys- 
tem's wiring. 



8-53 



Procedure 2 

EAS00738 



1 . Main and ignition fuses 



►Check the main and ignition fuses for conti- 
nuity. 

Refer to "CHECKING THE FUSES" in chap- 
ter 3. 



►Are the main and ignition fuses OK? 



o 



YES 



t 



NO 



Replace the fuse(s). 



2. Battery 



• Check the condition of the battery. 
Refer to "CHECKING AND CHARGING 
THE BATTERY" in chapter 3. 



m 



Minimum open-circuit voltage 
12.8 V or more at 20°C 



■ Is the battery OK? 







YES 



* 



NO 



•Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



EXUP SYSTEM 



ELEC 


+ 



4. Engine stop switch 



» Check the engine stop switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



Is the engine stop switch OK? 



o 



YES 



# 



NO 



Replace the right 
handlebar switch. 



5. Wiring 



►Check the entire EXUP system's wiring. 
Refer to "CIRCUIT DIAGRAM". 



•Is the EXUP system's wiring properly con- 
nected and without defects? 



YES 


■ NO 


Replace the ignitor 
unit. 


Properly connect or 
repair the EXUP sys- 
tem's wiring. 





3. Main switch 



►Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 



» Is the main switch OK? 



o 



YES 



# 



NO 



Replace the main 
switch. 



8-54 



SELF-DIAGNOSIS 



ELEC 


+ 



SELF-DIAGNOSIS 

The FZS1000 features a self-diagnosing system for the following circuit(-s): 

•Throttle position sensor 

•EXUP 

•Speed sensor 

• Emargency stop switch 
If any of these circuits are defective, their respective condition codes will be displayed on the tachome- 
ter when the main switch is set to "ON" (irrespective of whether the engine is running or not) 



Circuit 


Defect(-s) 


System response 


Condition code 


Throttle posi- 
tion sensor 


•Disconnected 
•Short-circuit 
• Locked 


•The ignitor unit stays set to the 
wide-open throttle ignition timing. 
The motorcycle can be ridden. 

•The tachometer displays the 
condition code. 


3,000 r/min 


EXUP 


•Improper 
connection 
•Short-circuit 


•The EXUP valve stays in the open 
position for three seconds and 
then the servomotor shuts off. The 
motorcycle can be ridden. 

•The tachometer displays the 
condition code. 


7,000 r/min 


•Servomotor is 
locked. 


•The servomotor's power supply is 
constantly inteerupted so that it 
will not burn out. The motorcycle 
can be ridden. 

•The tachometer displays the 
condition code. 


Speed sensor 


•Improper 
connection 


•The tachometer displays the 
condition code. 


4,000 r/min 


Emargency 
stop switch 


•Disconnected 
•Short-circuit 
•Fail angle 


•The tachometer displays the 
condition code. 
• Ignition system cutoff. 


9,000 r/min 



8-55 



SELF-DIAGNOSIS 



ELEC 


+ 



Tachometer display sequence 



Revolution o r/min ... 3 seconds 

( x 1 3 r/min) (g) Condition code ... 2.5 seconds 

(3) Engine speed ... 3 seconds 



10 



5-- 



© 




J I I l_l 



© 



© 



i i i 



10 

© 



Tachometer display 



Engine speed 



i i i i i 



© 



15 
© 



J—L 



© 



I I I L_L 



20 



© 



© 



25 



-f- Time (seconds) 



When more than one item is being monitored, the tachometer needle displays the condition codes in 
ascending order, cycling through the sequence repeatedly. 
If the engine is stopped, the engine speed (3) is r/min. 



8-56 



SELF-DIAGNOSIS 



ELEC 


+ 



TROUBLESHOOTING 



The tachometer starts to display the self- 
diagnosis sequence. 



Check: 

1 . Throttle position sensor 

2. EXUP 

3. Speed sensor 

4. Emargency stop switch 

NOTE: 



•Before troubleshooting, remove the following 
part(-s): 

1) Rider seat 

2) Fuel tank 

3) Air filter case 

•Troubleshoot with the following special 
tool(-s). 



y- 



Pocket tester 
90890-03112 



1. Throttle position sensor 

CIRCUIT DIAGRAM 



B |y/b| ■ | B/L | Gy | - | Gy 


\m\ 




Y 


Sb 




oX 


I L 




W/R 


Br/B 




y/gX 


B/r| B/y| ■ I W I B I - | L/R 



em 




© Throttle position sensor 
@) Ignitor unit 



1 . Wire harness 



•Check the wire harness for continuity. 

Refer to "CIRCUIT DIAGRAM". 
• Is the wire harness OK? 



o 



YES 



f 



NO 



Repair or replace the 
wire harness. 



2. Throttle position sensor 



►Check the throttle position sensor for conti- 
nuity. 

Refer to "CHECKING AND ADJUSTING 
THE THROTTLE POSITION SENSOR" in 
chapter 6. 
► Is the throttle position sensor OK? 



o 



YES 



f 



NO 



Replace the ignitor 
unit. 



Replace the throttle 
position sensor. 



8-57 



SELF-DIAGNOSIS 



2. EXUP 

CIRCUIT DIAGRAM 




(y>) EXUP servomotor 
@ Ignitor unit 



ELEC 


+ 



2. EXUP servomotor 



• Check the EXUP servomotor for continuity. 
Refer to "EXUP SYSTEM". 

• Is the EXUP servomotor OK? 







YES 



* 



NO 



Replace the ignitor 
unit. 



Replace the EXUP 
servomotor. 



1 . Wire harness 



•Check the wire harness for continuity. 

Refer to "CIRCUIT DIAGRAM". 
• Is the wire harness OK? 



o 



YES 



f 



NO 



Repair or replace the 
wire harness. 



8-58 



SELF-DIAGNOSIS 



3. Speed sensor 

CIRCUIT DIAGRAM 



|y;b| -IbTlIgvI -k 



m 



,B/r| B/y| - I W I B I - | L/R 



is: 






T 



*H© 



© 



L_ 



-<5- 



© ©] j 



© 



© 



© 



I 



© Ignitor unit 
@) Speed sensor 



i ■ ©i 

Lli 






l__©_4: 



| ©_£. 

\®M\ 



ELEC 


+ 



1 . Wire harness 



►Check the wire harness for continuity. 
Refer to "CIRCUIT DIAGRAM". 



• Is the wire harness OK? 



o 



YES 



# 



NO 



Replace the speed 
sensor. 



* 



BAD 



Replace the ignitor 
unit. 



Repair or replace the 
wire harness. 



8-59 



SELF-DIAGNOSIS 



4. Emargency stop switch 

CIRCUIT DIAGRAM 



|y/b| - MGy|~[Gy 



XR/W_ _X_Sb.__0_)< 



)fl L | - | W/r| Br/B | - |y/g[X 

b/y| - I w 



T 




.B/Y B/YJ 



IB/Y B/Y- 
B/R B/rJ_ 



© rzfc T w3 



©H; 



T 



4-f© 



iii 







H 



L. 



(Q) Emargency stop switch 
© Ignitor unit 



ELEC 


+ 



1 . Wire harness 



►Check the wire harness for continuity. 
Refer to "CIRCUIT DIAGRAM". 



• Is the wire harness OK? 



o 



YES 



# 



NO 



Replace the emar- 
gency stop switch. 



* 



BAD 



Replace the ignitor 
unit. 



Repair or replace the 
wire harness. 



8-60 



TRBL 
SHTG 


9 

• 



CHAPTER 9 
TROUBLESHOOTING 

STARTING PROBLEMS 

ENGINE 9-1 

FUEL SYSTEM 9-1 

ELECTRICAL SYSTEMS 9-2 

INCORRECT ENGINE IDLING SPEED 

ENGINE 9-2 

FUEL SYSTEM 9-2 

ELECTRICAL SYSTEMS 9-2 

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 

ENGINE 9-3 

FUEL SYSTEM 9-3 

FAULTY GEAR SHIFTING 

SHIFTING IS DIFFICULT 9-3 

SHIFT PEDAL DOES NOT MOVE 9-3 

JUMPS OUT OF GEAR 9-3 

FAULTY CLUTCH 

CLUTCH SLIPS 9-4 

CLUTCH DRAGS 9-4 

OVERHEATING 

ENGINE 9-4 

COOLING SYSTEM 9-4 

FUEL SYSTEM 9-4 

CHASSIS 9-4 

ELECTRICAL SYSTEMS 9-4 

OVERCOOLING 

COOLING SYSTEM 9-5 

POOR BRAKING PERFORMANCE 9-5 

FAULTY FRONT FORK LEGS 

LEAKING OIL 9-5 

MALFUNCTION 9-5 

UNSTABLE HANDLING 9-6 



TRBL 
SHTG 


9 

• 



FAULTY LIGHTING OR SIGNALING SYSTEM 

HEADLIGHT DOES NOT LIGHT 9-7 

HEADLIGHT BULB BURNT OUT 9-7 

TAIL/BRAKE LIGHT DOES NOT LIGHT 9-7 

TAIL/BRAKE LIGHT BULB BURNT OUT 9-7 

TURN SIGNAL DOES NOT LIGHT 9-7 

TURN SIGNAL BLINKS SLOWLY 9-7 

TURN SIGNAL REMAINS LIT 9-7 

TURN SIGNAL BLINKS QUICKLY 9-7 

HORN DOES NOT SOUND 9-7 



TROUBLESHOOTING 



TRBL 
SHTG 


9 

• 



TROUBLESHOOTING 

NOTE: 

The following guide for troubleshooting does not cover all the possible causes of trouble. It should be 
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for 
checks, adjustments, and replacement of parts. 



STARTING PROBLEMS 

ENGINE 

Cylinder(s) and cylinder head(s) 
•Loose spark plug 
•Loose cylinder head or cylinder 

• Damaged cylinder head gasket 

• Damaged cylinder gasket 
•Worn or damaged cylinder 

• Incorrect valve clearance 

• Improperly sealed valve 

• Incorrect valve-to-valve-seat contact 

• Incorrect valve timing 
•Faulty valve spring 
•Seized valve 



Piston(s) and piston ring(s) 
•Improperly installed piston ring 
•Damaged, worn or fatigued piston ring 
•Seized piston ring 
•Seized or damaged piston 

Air filter 
• Improperly installed air filter 
•Clogged air filter element 

Crankcase and crankshaft 
•Improperly assembled crankcase 
•Seized crankshaft 



FUEL SYSTEM 

Fuel tank 
•Empty fuel tank 
•Clogged fuel filter 
•Clogged fuel strainer 
•Clogged fuel tank drain hose 
•Clogged rollover valve 
•Clogged rollover valve hose 
•Deteriorated or contaminated fuel 

Fuel pump 
•Faulty fuel pump 
• Faulty fuel pump relay 

Fuel cock 
•Clogged or damaged fuel hose 



Carburetor(s) 
•Deteriorated or contaminated fuel 
•Clogged pilot jet 
•Clogged pilot air passage 
•Sucked-in air 

• Damaged float 
•Worn needle valve 

• Improperly installed needle valve seat 
•Incorrect fuel level 

•Improperly installed pilot jet 
•Clogged starter jet 

• Faulty starter plunger 

• Improperly adjusted starter cable 



9-1 



TROUBLESHOOTING 



TRBL 
SHTG 


9 

• 



ELECTRICAL SYSTEMS 

Battery 

• Discharged battery 
•Faulty battery 

Fuse(s) 
•Blown, damaged or incorrect fuse 
•Improperly installed fuse 

Spark plug(s) 

• Incorrect spark plug gap 

• Incorrect spark plug heat range 
•Fouled spark plug 

•Worn or damaged electrode 
•Worn or damaged insulator 

• Faulty spark plug cap 

Ignition coil(s) 
•Cracked or broken ignition coil 
•Broken or shorted primary or secondary 
coils 

• Faulty spark plug lead 



Ignition system 
•Faulty ignitor unit 
•Faulty pickup coil 
•Broken generator rotor woodruff key 

Switches and wiring 
•Faulty main switch 

• Faulty engine stop switch 
•Broken or shorted wiring 
•Faulty neutral switch 
•Faulty start switch 
•Faulty sidestand switch 
•Faulty clutch switch 
•Improperly grounded circuit 
•Loose connections 

Starting system 
•Faulty starter motor 
•Faulty starter relay 

• Faulty starting circuit cutoff relay 
•Faulty starter clutch 



INCORRECT ENGINE IDLING SPEED 

ENGINE 

Cylinder(s) and cylinder head(s) 

• Incorrect valve clearance 

• Damaged valve train components 

Air filter 
•Clogged air filter element 

FUEL SYSTEM 

Carburetor(s) 

• Faulty starter plunger 

• Loose or clogged pilot jet 

• Loose or clogged pilot air jet 

• Damaged or loose carburetor joint 
•Improperly synchronized carburetors 
•Improperly adjusted engine idling speed 

(throttle stop screw) 

• Improper throttle cable free play 
•Flooded carburetor 

•Faulty air induction system 



ELECTRICAL SYSTEMS 

Battery 

• Discharged battery 
•Faulty battery 

Spark plug(s) 

• Incorrect spark plug gap 

• Incorrect spark plug heat range 
•Fouled sparkplug 

•Worn or damaged electrode 
•Worn or damaged insulator 
•Faulty spark plug cap 

Ignition coil(s) 
•Broken or shorted primary or secondary 
coils 

• Faulty spark plug lead 
•Cracked or broken ignition coil 

Ignition system 
•Faulty ignitor unit 
•Faulty pickup coil 
•Broken generator rotor woodruff key 



9-2 



TROUBLESHOOTING 



POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 

Refer to "STARTING PROBLEMS". 



TRBL 
SHTG 


9 

• 



ENGINE 

Air filter 
•Clogged air filter element 



FUEL SYSTEM 

Carburetor(s) 
•Faulty diaphragm 
•Incorrect fuel level 
• Loose or clogged main jet 

Fuel pump 
•Faulty fuel pump 



FAULTY GEAR SHIFTING 

SHIFTING IS DIFFICULT 

Refer to "CLUTCH DRAGS". 

SHIFT PEDAL DOES NOT MOVE 

Shift shaft 
• Improperly adjusted shift rod 
•Bent shift shaft. 



JUMPS OUT OF GEAR 

Shift shaft 
•Incorrect shift pedal position 
•Improperly returned stopper lever 

Shift forks 
•Worn shift fork 



Shift drum and shift forks 

• Foreign object in a shift drum groove 
•Seized shift fork 

• Bent shift fork guide bar 

Transmission 
•Seized transmission gear 
•Foreign object between transmission 
gears 
•Improperly assembled transmission 



Shift drum 
•Incorrect axial play 
•Worn shift drum groove 

Transmission 
•Worn gear dog 



9-3 



TROUBLESHOOTING 



TRBL 
SHTG 


9 

• 



FAULTY CLUTCH 

CLUTCH SLIPS 

Clutch 
•Improperly assembled clutch 
•Improperly adjusted clutch cable 
•Loose or fatigued clutch spring 
•Worn friction plate 
•Worn clutch plate 

Engine oil 
•Incorrect oil level 
• Incorrect oil viscosity (low) 
•Deteriorated oil 



CLUTCH DRAGS 

Clutch 
•Unevenly tensioned clutch springs 
•Warped pressure plate 
•Bent clutch plate 
•Swollen friction plate 
•Bent clutch push rod 
•Broken clutch boss 
•Burnt primary driven gear bushing 
•Match marks not aligned 

Engine oil 
•Incorrect oil level 

• Incorrect oil viscosity (high) 

• Deteriorated oil 



OVERHEATING 

ENGINE 

Clogged coolant passages 
•Cylinder head(s) and piston(s) 
•Heavy carbon buildup 

Engine oil 
•Incorrect oil level 

• Incorrect oil viscosity 
•Inferior oil quality 

COOLING SYSTEM 

Coolant 

• Low coolant level 

Radiator 

• Damaged or leaking radiator 
•Faulty radiator cap 

• Bent or damaged radiator fin 

Water pump 

• Damaged or faulty water pump 
•Thermostat 

•Thermostat stays closed 
•Oil cooler 

•Clogged or damaged oil cooler 
•Hose(s) and pipe(s) 

• Damaged hose 
•Improperly connected hose 

• Damaged pipe 
•Improperly connected pipe 



FUEL SYSTEM 

Carburetor(s) 

• Incorrect main jet setting 
•Incorrect fuel level 

• Damaged or loose carburetor joint 

Air filter 
•Clogged air filter element 

CHASSIS 

Brake(s) 

• Dragging brake 

ELECTRICAL SYSTEMS 

Spark plug(s) 

• Incorrect spark plug gap 

• Incorrect spark plug heat range 

Ignition system 
•Faulty ignitor unit 



9-4 



TROUBLESHOOTING 



TRBL 
SHTG 


9 

• 



OVERCOOLING 

COOLING SYSTEM 

Thermostat 
•Thermostat stays open 



POOR BRAKING PERFORMANCE 

•Worn brake pad 

•Worn brake disc 

•Air in hydraulic brake system 

•Leaking brake fluid 

• Faulty brake caliper seal 
•Loose union bolt 

• Damaged brake hose 

•Oil or grease on the brake disc 
•Oil or grease on the brake pad 

• Incorrect brake fluid level 



FAULTY FRONT FORK LEGS 

LEAKING OIL 

• Bent, damaged or rusty inner tube 
•Cracked or damaged outer tube 
•Improperly installed oil seal 
•Damaged oil seal lip 
•Incorrect oil level (high) 

•Loose damper rod bolt 

• Damaged damper rod bolt copper washer 
•Cracked or damaged cap bolt O-ring 



MALFUNCTION 

• Bent or damaged inner tube 

• Bent or damaged outer tube 

• Damaged fork spring 

•Worn or damaged outer tube bushing 

• Bent or damaged damper rod 

• Incorrect oil viscosity 
•Incorrect oil level 



9-5 



TROUBLESHOOTING 



TRBL 
SHTG 


9 

• 



UNSTABLE HANDLING 

Handlebar 
•Bent or improperly installed handlebar 

Steering head components 
•Improperly installed upper bracket 
•Improperly installed lower bracket 

(improperly tightened ring nut) 
•Bent steering stem 

• Damaged ball bearing or bearing race 

Front fork leg(s) 
•Uneven oil levels (both front fork legs) 

• Unevenly tensioned fork spring 
(both front fork legs) 

•Broken fork spring 

• Bent or damaged inner tube 

• Bent or damaged outer tube 

Swingarm 
•Worn bearing or bushing 

• Bent or damaged swingarm 



Rear shock absorber assembly(-ies) 

• Faulty rear shock absorber spring 
•Leaking oil or gas 

Tire(s) 
•Uneven tire pressures (front and rear) 

• Incorrect tire pressure 
•Uneven tire wear 

Wheel(s) 

• Incorrect wheel balance 

• Deformed cast wheel 
•Damaged wheel bearing 

• Bent or loose wheel axle 
•Excessive wheel runout 

Frame 
•Bent frame 

•Damaged steering head pipe 
•Improperly installed bearing race 



9-6 



TROUBLESHOOTING 



TRBL 
SHTG 


9 

• 



FAULTY LIGHTING OR SIGNALING 

HEADLIGHT DOES NOT LIGHT 

•Wrong headlight bulb 

•Too many electrical accessories 

•Hard charging 

• Incorrect connection 
•Improperly grounded circuit 

• Poor contacts (main or light switch) 
•Burnt-out headlight bulb 

HEADLIGHT BULB BURNT OUT 

•Wrong headlight bulb 
•Faulty battery 
•Faulty rectifier/regulator 
•Improperly grounded circuit 
•Faulty main switch 
•Faulty light switch 
•Headlight bulb life expired 

TAIL/BRAKE LIGHT DOES NOT LIGHT 

•Wrong tail/brake light bulb 
•Too many electrical accessories 

• Incorrect connection 
•Burnt-out tail/brake light bulb 

TAIL/BRAKE LIGHT BULB BURNT OUT 

•Wrong tail/brake light bulb 
•Faulty battery 

• Incorrectly adjusted rear brake light switch 
•Tail/brake light bulb life expired 



SYSTEM 

TURN SIGNAL DOES NOT LIGHT 

• Faulty turn signal switch 
•Faulty turn signal relay 
•Burnt-outturn signal bulb 

• Incorrect connection 

• Damaged or faulty wire harness 
•Improperly grounded circuit 
•Faulty battery 

•Blown, damaged or incorrect fuse 

TURN SIGNAL BLINKS SLOWLY 

•Faulty turn signal relay 
•Faulty main switch 

• Faulty turn signal switch 

• Incorrect turn signal bulb 

TURN SIGNAL REMAINS LIT 

•Faulty turn signal relay 
•Burnt-outturn signal bulb 

TURN SIGNAL BLINKS QUICKLY 

• Incorrect turn signal bulb 
•Faulty turn signal relay 
•Burnt-outturn signal bulb 

HORN DOES NOT SOUND 

•Improperly adjusted horn 

• Damaged or faulty horn 
•Faulty main switch 
•Faulty horn switch 
•Faulty battery 

•Blown, damaged or incorrect fuse 
•Faulty wire harness 



9-7 



FZS1000 2001 WIRING DIAGRAM (EUR) 



J© 



t 




t A 


fw 


R/G 


G, R | 


g;r 


R/G 


w|| 


[y/b 


W 


B/lJ I B/L 


B/R 


yb|| 






MA,N HARNESS 


C0RD.HEADLIGHT2 



(A) 










fR/Y|w/Y|R/w|-^-|Dg|G I l| 
|g/b| Y I Uy| B I L7B| Ch |sb/w| LR | 




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B/Y 


Fwl 




| L/R |sd/w| Ch |l7B | B |uY Y G/b| 








MAIN HARNESS 


CORD.HEAD LIGHT 1 




© 
© 
® 
© 
© 
© 
© 
© 
© 
© 
© 
© 
© 
© 
© 
© 
© 
© 
© 
© 



Main switch @ 

Rectifier/regulator @ 

AC magneto @ 

Fuse (back up) © 

Battery © 

Starter relay © 

Fuse (main) © 

Starter motor @ 

Starting circuit cutoff relay © 

Sidestand switch © 

Fuel pump @ 

EXUP servo motor @ 

T.P.S. © 

Emargency stop switch @ 

Igniter © 

Ignition coil © 

Spark plug © 

Pickup coil @ 

Neutral switch © 

Speed sensor © 

Thermo unit © 

Meter assembly @ 

Fuel level warning light © 

Oil level warning light © 

Neutral indicator light © 

Tacho meter @ 

Combination meter @ 

Water temp warning light © 

Fuel gauge © 

Speedometer © 

Hi-beam indicator light © 

Turn signal indicator light (left) @ 
Turn signal indicator light (right) © 
Meter light 



B .. 
Br . 
Ch 
Dg 
G . 
Gy 
L . 

Lg 
o 
p . 

R. 

Sb 

W 

Y. 

B/G 

B/L 

B/R 

B/W 

B/Y. 

Br/B 

Br/L 



Black 

Brown 

Chocolate 

Dark green 

Green 

Gray 

Blue 

Light green 

Orange 

Pink 

Red 

Sky blue 

White 

Yellow 

Black/Green 

Black/Blue 

Black/ Red 

Black/White 

Black/Yellow 

Brown /Black 

Brown/Blue 



Oil level gauge 

Fuel sender 

Turn signal relay 

Handlebar switch (right) 

Front brake light switch 

Headlight switch 

Engine stop switch 

Start switch 

Horn 

Handlebar switch (left) 

Pass switch 

Dimmer switch 

Horn switch 

Clutch switch 

Hazard switch 

Turn signal switch 

Front turn signal light (left) 

Front turn signal light (right) 

Rear turn signal light (left) 

Rear turn signal light (right) 

Headlight 

Tail/brake light 

Fuse (turn signal) 

Fuse (ignition) 

Alarm 

Fuse (alarm) 

Fuse (headlight) 

Fuse (fan) 

Fan motor relay 

Fan motor 

Rear brake light switch 

Headlight relay (on/off) 

Head light relay (dimmer) 



Br/R . . 


. . Brown /Red 


Br/W . 


. . Brown/White 


G/B .. 


. . Green /Black 


G/R .. 


. . Green /Red 


G/W.. 


. . Green/White 


G/Y .. 


. . Green /Yellow 


L/B... 


. . Blue/Black 


L/R... 


. . Blue/ Red 


L/W .. 


. . Blue/White 


UY ... 


. . Blue/Yellow 


O/R .. 


. . Orange/ Red 


R/B... 


. . Red/Black 


R/G .. 


. . Red/Green 


R/W.. 


.. Red/White 


R/Y... 


. . Red/Yellow 


Sb/W. 


. . Sky blue/White 


W/R .. 


.. White/Red 


W/Y .. 


.. White/Yellow 


Y/B... 


. . Yellow/Black 


Y/G .. 


. . Yellow/Green 



FZS1000 N 2001 WIRING DIAGRAM (OCE) 




© Main switch 

© Rectifier/regulator 

(3) AC magneto 

Fuse (back up) 

® Battery 

© Starter relay 

© Fuse (main) 

® Starter motor 

© Starting circuit cutoff relay 

© Sidestand switch 

© Fuel pump 

© EXUP servo motor 

©T.P.S. 

@ Emargency stop switch 

© Igniter 

© Ignition coil 

© Spark plug 

@ Pickup coil 

© Neutral switch 

© Speed sensor 

©Thermo unit 

© Meter assembly 

© Fuel level warning light 

© Oil level warning light 

© Neutral indicator light 

© Tacho meter 

© Combination meter 

© Water temp warning light 

© Fuel gauge 

@ Speedometer 

© Hi-beam indicator light 



B Black 

Br Brown 

Ch Chocolate 

Dg Dark green 

G Green 

Gy Gray 

L Blue 

Lg Light green 

O Orange 

P Pink 

R Red 

Sb Sky blue 

W White 

Y Yellow 

B/G .... Black/Green 

B/L Black/Blue 

B/R Black/ Red 

B/W .... Black/White 

B/Y Black/Yellow 

Br/B .... Brown/Black 

Br/L .... Brown/Blue 



i Turn signal indicator light (left) 

i Turn signal indicator light (right) 

i Meter light 

i Oil level gauge 

i Fuel sender 

i Turn signal relay 

i Handlebar switch (right) 

i Front brake light switch 

i Engine stop switch 

i Start switch 

i Horn 

i Handlebar switch (left) 

i Pass switch 

i Dimmer switch 

i Horn switch 

i Clutch switch 

i Turn signal switch 

i Front turn signal light (left) 

i Front turn signal light (right) 

i Rear turn signal light (left) 

i Rear turn signal light (right) 

i Headlight 

i Tail/brake light 

i Fuse (ignition) 

i Fuse (turn signal) 

i Fuse (headlight) 

i Fuse (fan) 

i Fan motor relay 

i Fan motor 

i Rear brake light switch 

i Head light relay (dimmer) 



Br/R. 

Br/W 

G/B 

G/R 

G/W 

G/Y 

L/B. 

L/R. 

L/W 

L/Y. 

O/R 

R/B. 

R/G 

R/W 

R/Y. 

Sb/W 

W/R 

W/Y 

Y/B. 

Y/G 



Brown /Red 

Brown/White 

Green/Black 

Green /Red 

Green/White 

Green/Yellow 

Blue/Black 

Blue/Red 

Blue/White 

Blue/Yellow 

Orange/ Red 

Red/Black 

Red/Green 

Red/White 

Red/Yellow 

Sky blue/White 

White/ Red 

White/Yellow 

Yellow/Black 

Yellow/Green